D E S I G N / B U I L D / R E PA I R JULY 2014

MORE THAN
1,000 COMPANIES
In Print & Online!

A review of this year’s

moldmaking product
developments alongside a
supplier sourcing grid
VOLUME 17 / NUMBER 7
a mold with a view...
towards production.

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From the Editor

Time to Tool Up THIS MONTH ON

moldmakingtechnology.com
MoldMaking Technology’s annual guide and online database
SUPPLIERS: moldmakingtechnology.com/suppliers
serve up more than 1,000 manufacturers, distributors and Browse the alphabetical list of moldmaking suppliers by name:
suppliers for the more than 200 product and service categories • Enter all, any portion, or the first letter of the company’s
name and click “Search.”
you use every day. • You can also search by product type. Type in a product
category name (e.g., type of software, type of machine)
Whether it is time to upgrade equipment, invest in and click “Search.”
alternative processes, try a new method, investigate
a new way of doing things or simply shop around, Search by moldmaking suppliers within the following categories:
this guide can lead you to an appropriate technol- • Additive Manufacturing
• Automation
ogy or service supplier who can help.
• Business Development/Strategies
Every year, MoldMaking Technology surveys and • CAD/CAM and Design-Related Equipment/Services
updates its supplier database to provide you with • Cutting Tools and Toolholders
the most current company contact information. • EDM Equipment and Supplies
We then pull from that database, along with special • Hot Runner Systems and Supplies
tips, features and product reviews published throughout the year to create • Inspection/Measurement
• Machining Centers and Machine Tools
this annual Technology Review and Sourcing Guide.
• Mold Components
The guide’s accurate, comprehensive, easy-to-read and easy-to-use data • Mold Maintenance, Repair and Surface Treatment
on today’s technology, equipment, products and services is the perfect com- • Mold Materials
panion to your decision-making process. Each section includes key supplier • Moldmaking Equipment and Accessories
profiles that precede sourcing grids tailored to match suppliers with their • Molds/Tools/Dies
respective product/service offerings (advertisers are noted in boldface type), • Services
followed by technical product and service reviews, and tips and features. NEW PRODUCTS
The year’s latest moldmaking product developments within mold engi- moldmakingtechnology.com/products/new
neering/design, build and maintenance/repair are broken down into the This list is a comprehensive collection of product announce-
following 10 sections: ments provided by companies. You may search for specific
1. Software product information or browse to stay updated.
2. Additive Manufacturing ZONES
3. Mold Materials moldmakingtechnology.com/zones
4. Hot Runners This special area of MMT Online is where you can find deep
5. Mold Components collections of information on technology-specific suppliers,
6. Cutting Tools products and other important business and management topics,
which include past MoldMaking Technology articles relevant to
7. Machining
the topic, products and suppliers. Plus, you can search articles
8. EDM within each zone for more specific information.
9. Inspection/Measurement • Additive Manufacturing • Micromachining
10. Mold Maintenance, Repair and Surface Treatment • Automation • Mold Components
The data within this year’s condensed grids appears in its entirety • CAD/CAM and • Mold Maintenance
online at moldmakingtechnology.com/suppliers. We encourage you to Other Software and Repair
• Cutting Tools • Mold Materials
continue your search for even more of the latest in supplier and product • EDM • Surface Treatment
information by visiting the various zones at moldmakingtechnology.com. • Hot Runners • Business Strategies
We hope this annual guide becomes a vital part of your purchasing pro- • Inspection/Measurement • Mold Flow and Simulation
cess and serves as a tool to help meet all of your mold manufacturing needs. • Large Molds • End Markets
Please contact us at 800-579-8809 or cfuges@gardnerweb.com with any • Machining • IMTS 2014
comments and/or feedback. END MARKETS
Happy Shopping! • Aerospace/Defense
• Automotive/Transportation
• Consumer
• Electronics
Christina M. Fuges • Energy/Power Generation
• Medical/Optical/Dental
Editorial Director • Packaging

2 MoldMaking Technology July 2014

Contents July 2014 Volume 17 / Number 7

Publisher
5 Product/Service Sections Claude J. Mas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cmas@gardnerweb.com
Products and services are grouped into the following Metalworking Group Publisher
10 categories. Travis J Egan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tegan@gardnerweb.com
Editorial Director
Christina M. Fuges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cfuges@gardnerweb.com
Relevant supplier profiles precede an alphabetical listing
of suppliers within a sourcing grid tailored to match Senior Editor
Matthew Danford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mdanford@gardnerweb.com
suppliers with their respective products and service
Managing Editor
followed by technical product releases. Advertisers are El McKenzie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . emckenzie@gardnerweb.com
noted in boldface type. Database Manager
Taylor Wedmore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . twedmore@gardnerweb.com
5 Software
Art Director
13 Additive Manufacturing Carla M. Turner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cturner@gardnerweb.com
Advertising Production Manager
19 Mold Materials Becky Helton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bhelton@gardnerweb.com

31 Hot Runners 6915 Valley Avenue

Cincinnati OH 45244-3029
41 Mold Components P 513-527-8800
Fax 513-527-8801
61 Cutting Tools gardnerweb.com
moldmakingtechnology.com
85 Machining
Richard G. Kline, CBC | President
101 EDM
Melissa Kline Skavlem | COO
109 Inspection/Measurement Richard G. Kline, Jr. | Group Publisher
Tom Beard | Senior V.P., Content
115 Mold Maintenance, Repair & Surface Treatment Steve Kline, Jr. | Director of Market Intelligence
Ernest C. Brubaker | Treasurer
128 MoldMaking Marketplace William Caldwell | Advertising Manager
Ross Jacobs | Circulation Director
128 Ad Index Jason Fisher | Director of Information Services
Kate Hand | Senior Managing Editor
Jeff Norgord | Creative Director
For more product and supplier information,
Rhonda Weaver | Creative Department Manager
visit moldmakingtechnology.com
Dave Necessary | Senior Marketing Manager
Allison Kline Miller | Director of Events

ALSO PUBLISHER OF
• Modern Machine Shop • IMTS Directory
• Products Finishing • Products Finishing Directory
• Plastics Technology / PT Handbook • NPE Offcial Show Directory
• Production Machining • Automotive Design & Production
• High-Performance Composites • Composites Technology

Moldmaking Technology (ISSN 1098-3198) is published monthly and copyright © 2014 by

Cover images (left to right) courtesy of Sandvik; Cimatron and Sable Engineering; Mold Design Inc.;
and Wisconsin Engraving.
Gardner Business Media Inc. 6915 Valley Ave., Cincinnati, OH 45244-3029. Telephone: (513)
527-8800. Printed in U.S.A. Periodicals postage paid at Cincinnati, OH and additional mailing
offces. All rights reserved.
POSTMASTER: Send address changes to Moldmaking Technology Magazine, 6915 Valley
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CANADA POST: Canada Returns to be sent to IMEX Global Solutions, P.O. Box 25542, London,
ON N6C 6B2. Publications Mail Agreement #40612608.
The information presented in this edition of Moldmaking Technology is believed to be
accurate. In applying recommendations, however, you should exercise care and normal pre-
cautions to prevent personal injury and damage to facilities or products. In no case can the
authors or the publisher accept responsibility for personal injury or damages which may occur
in working with methods and/or materials presented herein, nor can the publisher assume
responsibility for the validity of claims or performance of items appearing in editorial pre-
sentations or advertisements in this publication. Contact information is provided to enable
interested parties to conduct further inquiry into specifc products or services.

moldmakingtechnology.com 3
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 Pages 5 to 12

Software
Pages xxx to xxx

Image courtesy of Mastercam/CNC Software.

moldmakingtechnology.com 5
Software Pages
Pg.55to
to12
9

Delcam Phone: 1-877-335-2261

3280 Electricity Drive
Windsor, ON N8W 5J1 northamerica@delcam.com
delcam-na.com
delcam.tv

PRODUCTS/SERVICES

Delcam PowerMILL Delcam FeatureCAM Delcam PartMaker Vortex: Revolutionizing

has advanced machining
strategies, to minimize manu-
facturing time and maximize
finish quality. PowerMILL has
high-speed finishing, multi-
axis machining, exceptionally
fast calculations and powerful
toolpath editing. Uniquely,
PowerMILL both foreground
and background processes.
All toolpaths are fully multi-
threaded letting you get NC
programs to your machine tools
in the shortest possible time.
automates machining
processes, by minimizing
programming times and
increasing productivity.
FeatureCAM is an easy-to-
use CAM software program
for milling machines, turning
and turn/mill centers, and
wire EDMs. FeatureCAM’s
advanced feature-based and
knowledge-based technolo-
gies automates the creation
of reliable NC Code.
is CNC programming that
reduce set-up time across all
of your machine platforms.
PartMaker is the CAD/CAM
choice of many of the world’s
leading production machining
organizations. PartMaker
applies two unique patented
technologies for the program-
ming of multi-axis Turn-Mill
Centers and Swiss-type lathes.
High Speed Roughing
Vortex controls the maximum
engagement angle of the cutter
in the material. Angle calcu-
lated for the programmed step
over is never exceeded, even in
internal corners. This allows for
optimal cutting conditions to
be maintained throughout the
toolpath. Designed for Solid
Carbide Tooling it integrates
seamlessly with PowerMILL,
FeatureCAM, PartMaker and
Delcam for SolidWorks.

WEBSITE PRODUCT CATEGORIES

Delcam design,
manufacturing and
inspection software
can be viewed at
delcam-na.com. For
video testimonials
and product
demonstration,
go to delcam.tv.
delcam-na.com
• CAD (Computer Aided Design)
• CAM (Computer Aided Manufacturing)
• CIM (Computer Integrated Manufacturing)
• Data Translation Software
• Manufacturing Automation Software
• Mold Design Software
• NC Simulation and Verifcation Software
• Product Design and Development Software
• Reverse Engineering Software

6 MoldMaking Technology July 2014

Software

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COMPANY Advertisers are listed in bold type See Ad 1 2 3 4 5 6
3D Systems, Rock Hill, SC, 803-326-3900 1 5
Algoryx, Inc., Palos Verdes Peninsula, CA, 310-820-0987 x100
Autodesk, Inc., San Rafael, CA, 415-507-5000 1 2 5
Beaumont Technologies, Inc., Erie, PA, 814-899-6390 2 4
BobCAD-CAM, Clearwater, FL, 727-442-3554 1 5
CAE Services Corporation, Batavia, IL, 630-761-9898 2 4
CAMWorks/Geometric Americas, Inc., Scottsdale, AZ, 480-367-0132 1 2 5 6
Celeritive Technologies, Moorpark, CA, 805-895-6707 5
CGS North America, Inc., Oldcastle, ON, 519-737-6009 11 1 5
CGTech, Irvine, CA, 949-753-1050 1 2 5
Cimatron Technologies, Inc., Novi, MI, 248-596-9700 1 5 6
Delcam, Windsor, ON 7 1 5
DZynSource LLC, East Killingly, CT, 860-933-2917 1 2
Edgecam by Vero Software, Forest Lake, MN, 800-875-7232 1 2 5 6
Epicor Software Corporation, Dublin, CA, 949-585-4000
ESPRIT by DP Technology, Camarillo, CA, 805-388-6000 1 2 5 6
Exact JobBOSS, Bloomington, MN
Gibbs and Associates, A Cimatron Company, Moorpark, CA, 805-523-0004 1 5
Hurco Companies Inc., Indianapolis, IN, 317-293-5309 1, 87
JDL Technical Services, Comber, ON, 519-919-7391
Kubotek USA Inc., Marlborough, MA, 508-229-2020 1 2 3 5
Makino, Auburn Hills, MI, 248-232-6200 6
Mason Dixon Design, Glen Rock, PA, 717-759-0391 128 4
Master3DGage, Anaheim, CA, 866-340-5551 1 3 5
Mastercam / CNC Software, Tolland, CT, 860-875-5006 1 2 3 5
Moldex3D, EPS FloTek, Naperville, IL, 630-778-7773 1 2 5 6
OPEN MIND Technologies USA Inc., Needham, MA, 339-225-4557 1 5
PTC Inc., Needham, MA, 781-370-5000 1 5
Siemens PLM Software, Plano, TX 1 2 3 5
Sigma Plastic Services Inc., Schaumburg, IL, 847-558-5600
SolidCAM Inc., Newtown, PA, 866-975-1115 1 2 5
SolidWorks Corp., Waltham, MA, 781-810-5011 1 2 5
SpaceClaim Corp., Concord, MA, 978-482-2100 1 2 5
SURFCAM by Vero Software, Thousand Oaks, CA, 800-787-392 1 2 5 6
Tebis America Inc., Troy, MI, 248-524-0430 1 3 5
TopSolid / Missler Software, Inc., Addison, IL, 630-889-8055 1 2 4 5 6
TST Tooling Software Technology, LLC, Clarkston, MI, 248-922-9293 1 2 3 4 5
Verisurf Software, Inc., Anaheim, CA, 714-970-1683 1 3 5 6
VISI by Vero Software, Forest Lake, MN, 800-875-7232 1 2 3 5 6
WorkNC by Vero Software, Southfeld, MI, 248-351-9300 1 2 5 6

For more supplier listings, go to moldmakingtechnology.com/suppliers

8 MoldMaking Technology July 2014

 Software Pages 5 to 12

Manufacturing Software Other Software

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7 8 9 10 11 12 13 14 15 16 17 WEBSITE
3dsystems.com
9 11 17 algoryx.com
8 11 12 16 17 autodesk.com
16 17 beaumontinc.com
bobcad.com
17 caeservices.com
9 12 camworks.com
celeritive.com
camtool.com
9 11 17 cgtech.com
9 13 17 cimatrontech.com
9 12 delcam-na.com
11 13 dzynsource.com
9 12 edgecam.com
11 epicor.com
9 dptechnology.com
8 11 14 15 jobboss.exactamerica.com
9 12 grdnr.gibbscam.com
7 hurco.com
7 8 11 13 jdltech.ca
9 12 kubotek3d.com
makino.com
mason-dixon-design.com
8 10 12 master3dgage.com
7 8 9 mastercam.com
17 epsfotek.com
9 openmind-tech.com
ptc.com
9 10 11 12 16 17 siemens.com/plm
17 3dsigma.com
9 solidcam.com
9 11 12 17 solidworks.com
spaceclaim.com
9 12 surfcam.com
9 11 12 tebis.com
12 topsolid.com
7 9 10 12 13 15 17 tst-software.com
10 12 verisurf.com
9 12 13 15 17 visicadcam.com
9 12 worknc.com

Image courtesy of Missler.

moldmakingtechnology.com 9
Software
CAD/CAM Update Eases Job Startup
The latest version of Cam-Tool CAD/CAM software from CGS North America
is designed for machining molds or dies that require minimal to no polishing.
Version 10.1 includes an expansion of the EZ Launcher feature, which eases job
startup, and the addition of a Corner Rad function to more toolpath types to
enable a smoother corner transition in finishing routines.
Other improvements include increased direct connection at startup with the
machine being programmed for; increased automated preparation of the tool
paths and selection of the areas to be machined through 2.5 Structures; and an
improved Protrusion Divide function for finishing; as well as fixes to known issues.
In addition, Version 4.1 of the software’s add-in to SolidWorks includes the
ability to apply 3D and 2D tool paths directly to the SolidWorks model and get the
same high-quality results as with Cam-Tool, the company says. This is designed
to minimize handwork and polishing on electrodes, inserts, slides, lifters, and
core and cavity components. Wire EDM capability also has been improved.
CGS North America Inc. / 519-737-6009 / camtool.com
Enterprise Software Helps Manage
Product Costs
The aPriori 2014r1 software platform offers enterprise capabilities
designed to help users better predict product costs, cost a wider
variety of types of products and parts, and identify and act on prod-
uct cost-reduction opportunities.
The platform provides real-time cost information on parts and
complete products. It also can read 3D CAD files to automatically
generate cost inputs, and uses intelligent cost models to determine
feasible manufacturing methods and product costs. The software
also allows users to leverage data hosted in other critical enterprise
applications to communicate product cost information between
all organizations involved in product definition and delivery. This
includes the import of complex engineering bills of materials from
ERP, PLM and other enterprise applications.
aPriori Inc. / 978-371-2006 / apriori.com
10 MoldMaking Technology July 2014
Machining Software Includes Mill-Turn Capabilities
Mastercam X7 from CNC Software Inc. features a variety of new capabilities,
including the Mill-Turn function for high-powered turning centers and full-
function machining centers. Mill-Turn is designed to streamline the program-
ming process with intelligent job setups and intelligent work plane selection
that eases the selection of the proper spindle and turret. The product’s Code
Expert interface incorporates an entire suite of tools for managing multitask-
ing applications.
Mastercam/CNC Software / 860-875-5006 / mastercam.com
Software Manages Tool Data
TDM Systems’ TDM (Tool Data Management) software is designed to be an
integrated solution for data acquisition and managing of tools, tool assemblies,
fixtures and setup equipment. Because the software interfaces with virtually all
major CAD/CAM programs, accurate tool data, 2D graphics and 3D models are
quickly available for “realistic” simulations, boosting process reliability.
The software houses tool data in a transparent, unified format, enabling
users to standardize tool inventories and reduce tool costs. The data is acces-
sible with a few mouse clicks, also reducing programming time.
TDM Systems / 847-605-1269 / tdmsystems.com
HSM Function Enables Faster Milling
While Reducing Tool Wear
The high-speed machining (HSM) capabilities of Gibbs and Associates’
GibbsCAM include the VoluMill function, designed to enable faster milling
cycles while simultaneously reducing tool wear. The function is said to gener-
ate tool paths optimized for high feed rates. It uses constant tool loading and
automatically chooses the best option for individual pockets, including plunge
speed and material removal rates, the company says.
GibbsCAM’s Multi-Task Machining (MTM) provides milling and turning
functions in a single interface, minimizing programming and maximizing effi-
ciency. The software’s settings automatically capture a multi-task machine’s
specific configuration and support all available utility operations and installed
optional equipment. According to Gibbs, MTM supports a variety of tool groups,
turrets and spindles, including those of Swiss-style machines. The software
also enables elimination of multiple setups, improving part quality and pro-
duction speed.
Gibbs and Associates / 805-523-0004 / gibbscam.com
NC Simulation Software Offers Features for
Multi-Axis Machining
NCSIMUL Machine 9 software from Spring Technologies is designed to
produce an NC simulation environment that is realistic, intuitive, integrated
and mobile, with extended features dedicated to multi-axis and multitasking
machining centers. In addition, the software can interconnect with other
company-wide software systems such as material requirements planning,
enterprise resource planning and manufacturing execution systems.
Spring Technologies (NCSIMUL Solutions) / 617-401-2197 /
springplm.com

CAM Software Offers Various Machining Strategies
Open Mind Technologies’ HyperMill 2013 CAM software features several strat-
egies designed to overcome typical machining challenges faced by tool and
mold manufacturers, including a rib milling cycle that automatically detects
grooves that need to be milled as deep, narrow cavities for ribs in molds. Steep
areas and floors are machined separately. Depending on the workpiece geom-
etry, the system selects a suitable roughing strategy, and contiguous areas
are completely machined. The software also features an extension for five-
axis contour offset finishing using barrel cutters. This strategy uses the large
effective radius of the barrel cutter with a point-milling contract style, allow-
ing for increased step-over distances between passes for free-form surfaces.
The integrated HyperMaxx roughing module combines optimal milling paths,
maximum material removal and short machining times. Ideally distributed
milling paths and dynamic feed rate adjustment to existing cutting conditions
ensure that milling always takes place at the fastest possible feed rate, the
company says. Machining is performed using climb milling, featuring a spiral
retraction of tool movements that increasingly approximate the required con-
tour as they reach the end. The tool path is calculated taking into consideration
chip volume, machine data, material to be cut and balanced movement.
Open Mind Technologies USA Inc. / 339-225-4557 /
openmind-tech.com
Software Pages 5 to 12
CAD/CAM Module Manages Mold Design Process
A CAD/CAM module for moldmakers and tool and die specialists, the newest
generation of Missler Software’s TopSolid’Mold has been fully integrated into
the company’s TopSolid 7 software. The module is designed to manage the
complete mold design process, including all changes occurring throughout
this stage.
New features include an easy-to-use, intuitive interface; a Powerful Split
module that is able to manage inserts from the split stage; intelligent stan-
dard components such as mold bases and ejector pins; a unique cooling circuit
design method; total control of mold data; optimized performances for heavy
modifications.
TopSolid/Missler Software Inc. / 630-889-8055 /
topsolid.com
VisualCAD/CAM Update Includes
Enhanced Modules
The 2014 version of MecSoft Corp.’s standalone CAD/CAM software suite,
VisualCAD/CAM, includes enhanced and improved VisualMill, VisualTurn,
VisualNest and VisualArt modules. Each of these modules runs integrated
inside the Visual CAD base design tool, and can be bought and licensed inde-
pendently. A free demo version of VisualCAD/CAM 2014 can be downloaded at
visualcadcam.com.
MecSoft Corp. / 949-654-8163 / mecsoft.com
3D CAM Software Adds
Adaptive Roughing Technology
The latest version of Surfcam 3D CAM software from Vero Software’s Surfcam
Inc. division includes adaptive roughing technology and a variety of other
enhancements designed for easier user and control in masking, chaining,
operations management and layering functionality. Surfcam 2014 R1 also
features additional updated CAD translators, postprocessors and an “editNC”
function.
Surfcam Inc. / 818-991-1960 / surfcam.com
Vero Software / 800-875-7232 / verosoftware.com
moldmakingtechnology.com 11
Software Software Pages 5 to 12

How to Test

Image courtesy of Sigma Plastic Services Inc.

Mold Design
Performance

By Dr. Marco Thornagel

When it comes to injection mold-
ing, it is common for companies
to rely on trial-and-error methods
to solve production problems.
Without process simulation, opera-
tors suggest a mold configuration
that “should work” for a specific
part geometry based on experi-
ence. Factors such as tempering
or processing times are defined
later, during the first production
trials. It is not uncommon to end
up with molds that require several
rework stages, as well as parts with
quality issues where the causes of these issues are not well- Simulation can be used to support the complete mold design process.
understood. All elements in the mold are considered, so that an exact prediction of the
Simulation technology can help avoid these typical process- processing conditions can save production time and troubleshooting effort.
ing problems while saving significant time and effort during
the development of a new mold. All the elements of the mold ly included in the simulation, including their exact location in
can be included in the process simulation. This allows the the mold, as well as the necessary material and electric power.
molder to run a virtual production, including all the process Even the control system can be defined. Instead of guessing
stages (preheating of the mold, injection and curing), not only at an appropriate mold temperature, the mold’s exact thermal
over one cycle, but over several production cycles. Through condition can be predicted, including the way it fluctuates
simulation, the mold’s performance can be evaluated com- over time.
pletely before the steel is even cut. Then, after the effect of the tempering system is simulated,
Historically, conventional injection molding tools have been factors in the mold that can compromise part quality can be
relied upon to predict the filling of the cavity. Many still think identified. Examples of virtual troubleshooting that can be
this is all simulation can do for them. However, simulation achieved through process simulation include cold spots in the
tools that are available nowadays are far more powerful. In mold where the material cures too late and irregular tempera-
addition to filling, curing reaction can be accurately predicted ture distributions that can produce uneven curing of parts
and thermal behavior can be precisely anticipated. produced in different cavities.
Simulation can help a company achieve its production goals
faster and become more profitable. It can analyze different
variables in the design of a new mold. Once the desired geom-
etry is determined, the process starts with the selection of the CONTRIBUTOR
injection point or gate type. With an understanding of the Dr. Marco Thornagel is executive director of Sigma Engineering GmbH.
flow behavior, as well as quality issues related to weld lines,
air gaps or jetting, the runner geometry can be defined. In this
stage, mold aspects such as cavity balance or pressure require- FOR MORE INFORMATION:
ments can be predicted. Christof Heisser or Matt Proske / Sigma Plastic Services Inc.
Once the part and runner are defined, the tempering of the 847-558-5600 / contact@3dsigma.com / 3dsigma.com
mold can be designed. The tempering elements can be precise-

12 MoldMaking Technology July 2014

 Pages 13 to 18

Additive Manufacturing

Image courtesy of Arburg Inc.

moldmakingtechnology.com 13
Additive Manufacturing

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COMPANY See Ad 1 2 3 4 5 6
3D Systems, Rock Hill, SC, 803-326-3900 1 3 4 5 6
3M Company, St. Paul, MN, 800-435-3082
AIM Plastics, Inc., Clinton Twp., MI, 586-954-2553
Armstrong Mold, East Syracuse, NY, 315-437-1517
Autodesk, Inc., San Rafael, CA, 415-507-5000 1
Capture 3D, Costa Mesa, CA, 714-546-7278 2
Clinkenbeard, Rockford, IL, 815-226-0291
Crescent Industries Inc., New Freedom, PA, 717-235-3844
Delcam, Windsor, ON 7 4
Direct Dimensions, Inc., Owings Mills, MD, 410-998-0880 4
DMG MORI, Hoffman Estates, IL, 847-593-5400 1 3
Dow Corning Corporation, Midland, MI, 989-496-6000
EnvisionTEC, Inc., Dearborn, MI, 313-436-4300 1 3 4
EOS of North America, Inc., Novi, MI, 248-306-0143 3 4 5 6
ExOne, North Huntingdon, PA, 724-863-9663 1 3 4 5
General Plastics Manufacturing Co., Tacoma, WA, 253-473-5000
GPI Prototype & Manufacturing Services, Inc., Lake Bluff, IL, 847-615-8900
Huntsman Advanced Materials, The Woodlands, TX, 281-719-4945
Laser Reproductions, Gahanna, OH, 614-552-6905
Linear Mold & Engineering, Livonia, MI, 734-422-6060
Matsuura Machinery USA, Fukui-City, MN, 651-484-9698 1 3
MC Machinery Systems, Inc., Wood Dale, IL, 630-616-5920 103 1 3
Mcor Technologies, Dunleer, Co Louth, , 353 41 6862800 1
Met-L-Flo Inc., Sugar Grove, IL, 630-409-9860 1 2 4 5 6
NextEngine, Santa Monica, CA, 310-883-1888 2 4
Optomec Inc., Albuquerque, NM, 505-761-8250 1 3 4
Paramount Industries, Inc., Langhorne, PA, 215-757-9611
Perceptron, Plymouth, MI, 734-414-6100 3 4
Proto Labs, Inc., Maple Plain, MN, 763-479-3680
Quickparts.com, Inc., Atlanta, GA, 770-901-3200
RedEye, Eden Prairie, MN, 866-882-6934 4
Renishaw Inc., Hoffman Estates, IL, 847-286-9953 3 4
Roland DGA Corp., Irvine, CA, 949-727-2100 2 3 4 6
Schmit Prototypes, Menomonie, WI, 715-235-8474 4
Solidscape Inc., Merrimack, NH, 603-429-9700 1 4 5
Stratasys Inc., Eden Prairie, MN, 800-937-3010 1 3 4 5
Vista Technologies LLC, Vadnais Heights, MN, 651-653-0400 5
voxeljet AG, Friedberg, 0049 821 7483100 1 3 4
Xcentric Mold & Engineering Inc., Clinton Twp, MI, 586-598-4636
xlaFORM, Inc., Charlotte, NC, 704-906-0202 1

For more supplier listings, go to moldmakingtechnology.com/suppliers

14 MoldMaking Technology July 2014

 Additive Manufacturing Pages 13 to 18

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7 8 9 10 11 12 13 14 15 WEBSITE
7 8 10 11 12 15 3dsystems.com
7 3m.com/aerospace
9 10 11 12 aimplastics.com
9 10 11 12 armstrongmold.com
autodesk.com
8 14 capture3d.com
9 11 12 clinkenbeard.com
8 9 10 14 crescentind.com
delcam-na.com
8 9 10 12 14 dirdim.com
dmgmori-usa.com
7 dowcorning.com
envisiontec.com
7 eos.info
9 11 12 13 exone.com
7 9 10 generalplastics.com
8 9 10 11 12 13 14 gpiprototype.com
7 huntsman.com/advanced_materials
11 12 13 laserrepro.com
8 11 12 13 linearmold.com
matsuurausa.com
mcmachinery.com
mcortechnologies.com
7 8 9 10 11 12 13 14 15 metlfo.com
nextengine.com
optomec.com
8 9 10 11 12 13 14 paramountind.com
perceptron.com
9 10 12 13 protolabs.com
9 10 11 12 13 quickparts.com
10 11 12 redeyeondemand.com
11 renishaw.com
7 rolanddga.com
8 9 10 11 12 13 schmitprototypes.com
solid-scape.com
11 12 stratasys.com
8 9 10 11 12 13 vistatek.com
9 11 12 14 voxeljet.com
8 12 13 14 xcentricmold.com
9 12 xlaform.com
Image courtesy of Voxeljet.

moldmakingtechnology.com 15
Additive Manufacturing
Direct Metal Sintering Produces High-Density,
Non-Porous Parts
Direct metal sintering (DMS) technology allows the accurate, direct printing
of high-density, non-porous, chemically pure metal parts (such as this one
printed by 3D Systems), yielding high repeatability, reliability and quality.
Metal end-use parts and tooling inserts can be directly and quickly created
via this process, cutting out intermediate and time-consuming steps required
in traditional manufacturing. This includes complex parts and shapes that
would be nearly impossible to produce using traditional methods. In addition,
direct-metal-sintered tooling can be used in the production process within a
day or two after manufacture, rather than after waiting weeks for the tool-
ing to be machined. A selection of materials can
be used in DMS systems, including stainless
steel, tool steel, super
alloys, non-ferrous
alloys, precious
metals and alu-
mina used in the
aerospace, auto-
motive and medical
device industries.
3D Systems /
888-337-9786 /
3dsystems.com
Nylon FDM Material Offers Greater Strength
Stratasys offers a nylon material designed to offer greater resistance to
breaking and better impact strength than other fused deposition modeling
(FDM) materials. Specifically engineered for the company’s line of Fortus
3D production systems, FDM Nylon 12’s elongation-at-break specification is
said to surpass that of other 3D-printed nylon 12
materials by as much as 100 percent. This can
enable manufacturers in aerospace, auto-
motive, home appliance and consumer
electronics to create durable parts that
can stand up to high vibration, repeti-
tive stress or fatigue.
FDM Nylon 12 is available for the
Fortus 360, 400 and 900 systems.
It is initially being offered in
black and is paired with SR110,
a new soluble support material
that the company says is optimized
for the nylon material. Support
removal requires virtually no labor
and is conveniently washed away in
the same cleaning agent as other FDM-
soluble supports, Stratasys says.
Stratasys Inc. / 888-480-3548 /
stratasys.com
16 MoldMaking Technology July 2014
Additive Process
Builds Plastic Parts
without Molds
Arburg has developed the
Arburg Plastic Freeforming (AKF)
process and Freeformer machine
to additively manufacture indi-
vidual plastic parts without the
need for molds or predefined
cavities. In this process, 3D CAD
files are processed directly, standard plastic granulate is melted, droplets are
generated from the liquid melt, and a fully functional component is built up
from these droplets layer by layer.
The AKF process uses conventional plastic granulates rather than prefab-
ricated supplies such as powders or strands that can make the material, the
processing and therefore the parts more expensive. Because the Freeformer can
operate without support structures and therefore produces no waste, material
consumption is reduced and production is more cost-effective, the company says.
Arburg Inc. / 860-667-6500 / arburg.com
3D Sand Printing Builds Molds without Tooling
Voxeljet has developed a 3D printing process that can create sand molds and
cores for casting parts such as the diesel engine cylinder head pictured here.
According to Tom Mueller, principal of Thomas J. Mueller and Associates,
casting such a cylinder head requires several tools, including patterns for the
cope and drag (the top and bottom parts of the sand mold), and a number of
core boxes (molds used to create sand cores that will form undercut features
in the head). This process can take thousands of dollars and several weeks
to complete. Castings with complex flow situations, like cylinder heads and
pumps, often can only be optimized by an iterative design-build-test-redesign
process, he says. However, the cost and time required to create the tooling
for each design iteration makes the process very costly and time consuming.
With the Voxeljet process, molds and cores can be built without tooling in a
few days, making this iterative process more cost- and time-effective. In fact,
a designer can now simultaneously evaluate several design alternatives to
further cut the time required to optimize the design, Mueller says.
Voxeljet Technology GmbH / 49 821 7483100 / voxeljet.de

Hybrid Machine Performs Multiple Processes
DMG MORI’s Lasertech 65 hybrid solution can do rough machining, deposition
and finishing on one machine, allowing a part such as the one pictured here
to be built and machined with five axes. The additive features grown off of the
central OD show the machine’s ability to reorient the part to build in different
directions within the cycle. The drilled holes and milled mating surfaces were
created using the machine’s conventional machining capability.
Parts such as this can be built
as much as 20 times faster than
with powder bed solutions, the
company says. Parts can also be
built up in sections, with milling
operations used on important
areas in between. Support struc-
tures are not necessary, and wall
thickness can range from 0.5 to
5 mm (0.020” to 0.2”).
Dr. Greg Hyatt, chief tech-
nology officer, explains that an
advantage of this process is that it can be used to build up a number of layers,
of the same or various alloys, which can then be machined to the required accu-
racy before the next layers are added. These part areas would not normally be
accessible for milling cutters, meaning hidden features can now be machined.
DMG MORI / 847-593-5400 / us.dmgmori.com
Laser Melting Creates Mold with Eight Complex Conformal Cooling Channels
The conformal temperature control arrangement pictured here requires com-
plicated design work—eight outlets of 3 mm (0.12”) in diameter and practically
identical flow conditions branching out from a 10-mm (0.40”) inlet. According
to Renishaw and LBC Engineering, this design guarantees uniform, highly
turbulent coolant flow and efficient heat transport in each channel. These
Additive Manufacturing Pages 13 to 18
New Metal Materials Suited for
Additive Manufacturing
EOS has expanded its materials portfolio to include two new metal alloys: EOS
Titanium Ti64ELI and EOS StainlessSteel 316L.
EOS Titanium Ti64ELI is a light metal alloy that is corrosion-resistant and
biocompatible, making it particularly suited for the manufacture of medical
implants. EOS StainlessSteel 316L also is corrosion-resistant, biocompatible
and well-suited for use in the medical industry, but it also can be used in the
manufacture of watches, jewelry and eyeglass frames, and in the aerospace
industry. Parts manufactured from this stainless alloy can be mechanically
post-processed or polished.
EOS’ metal materials portfolio also includes EOS NickelAlloy HX, a heat-
and corrosion-resistant nickel-chrome-iron-molybdenum alloy that offers
high strength and resistance to oxidization, even at temperatures as high as
1,200°C. It typically is processed with a layer thickness of 20 microns.
EOS / 248-306-0143 / eos.info
inserts were laser-generated on a Renishaw machine with a 0.5-mm (0.02”)
margin per wall. Conventionally made inserts cannot usually be pre-worked in
such detail before hardening, so this means reduced hardening work for cost
savings that partly offsets the cost of the laser melting process.
Renishaw Inc. / 847-286-9953 / renishaw.com
moldmakingtechnology.com 17
Additive Manufacturing Additive Manufacturing Pages 13 to 18

3D Sand Printing Benefits

By Christina M. Fuges
The most important benefit of 3D sand printing is the speed of
the process. “In a nutshell, if you look at the traditional way of
making a casting, you are months out before you get your first
casting, and with 3D sand printing you can have a casting in a
matter of days to a couple of weeks,” says Paul Susalla, Ford’s
section supervisor for rapid manufacturing.
If you are using tooling, it might be four months down the
road before you get your first part and realize that it’s not what
you want, he explains. Then the tooling must be changed.
“If you look at the product development cycle, Ford, GM and
Chrysler only give you X number of months to years to put it
on paper and then get it on the street,” he says. “As an engi-
neer, you only have a certain amount of time to get your part
right. The traditional method might give you only three shots
at getting the part right, but 3D sand printing allows you to
create multiple iterations at the same time because you are not
committed to tooling.”
According to Susalla, instead of one design, you’re looking at
five to six designs right off the bat, and then, within a matter
of weeks, you can have already tested those five or six designs,
made some engineering decisions, and come up with altera-

Image courtesy of Sam VarnHagen/Ford Motor Co.

tions or even new designs to test. So with 3D sand printing, you
have plenty of opportunities to optimize the design for quality,
cost, time, fuel economy, performance and safety, he says.
Another known benefit
At the end of the day, of 3D sand printing is that it
eliminates traditional design
with 3D sand printing, limitations. “You can make
Ford has plenty of something the way it wants
opportunities to optimize to be designed versus how
it can be manufactured,”
Ford Technologist Dennis DuBay removes sand that surrounds sand cast
the design for quality, Susalla says. molds for engine components made through Ford’s 3-D printing process at its
cost, time, fuel economy, He notes, however, that facility in Dearborn Heights, Michigan. Each fuel-effcient EcoBoost engine
when Ford makes a cylinder now in Ford vehicles was initially developed with 3-D sand prototyping.
performance and safety. head, the mold is shaped
exactly the same as it will be Both Susalla and Sears agree that an additional benefit of 3D
in production—with draft sand printing is that it promotes collaboration, helping them
angles and parting lines—so that the test part is representative as they work closely with manufacturing engineering when
of what will be coming out of the production process. they run into production issues.
According to Harold Sears, Ford additive manufacturing “We find things and realize ‘You know what, the plant’s
technical specialist, not following this protocol caused some going to have a problem with this,’” Sears says. “We then bring
problems for the company when it first adopted the sand the manufacturing and product engineering groups together
printing technology. “We weren’t making parts like they were and say, ‘Look, we made your prototypes and we discovered
in production, and we were getting fantastic testing,” he says. this, which is going to be an issue in production. You need to
“Then all of a sudden when we tooled up the part, we lost per- figure it out.’ Then the two groups get together to modify the
formance. You have to make it like it’s made in production.” designs to accommodate mass production.”

18 MoldMaking Technology July 2014

 Pages 19 to 30

Mold Materials
Pages xxx to xxx

Image courtesy of Cimatron and Sable Engineering.

moldmakingtechnology.com 19
Mold Materials Pages 19 to 30 Pg. 5

EDRO Engineering Californina – Pennsylvania –

and Specialty Steels, Inc. Germany
West: 800-368-3376
East & Midwest: 888-368-3376
Germany: +49 (0) 7805 91579-0

edro.com

PRODUCTS/SERVICES

Innovative Tooling Solutions

Specialty Steels, Custom Mold Bases and
Precision Machining Services
EDRO is a leading manufacturer of custom mold bases and
specialty steels for the plastics tooling industry. Backed by state-
of-the-art equipment, a skilled and experienced team, and a
painstaking dedication to quality, EDRO continually delivers the
finest custom mold bases available in the market with unmatched
precision and repeatability. EDRO also offers a comprehensive
line of premium tool steels, including our unique and innovative
proprietary steels:

RoyAlloy™ Stainless,
EDRO400™ Stainless, and
P1FM™. EDRO’s premium
tool steels are offered from
stock in the saw-cut or
machined condition with
quick delivery times.
Contact our team for further
information on EDRO’s
products and services.

WEBSITE PRODUCT CATEGORIES

EDRO is a leading manu- • Custom Mold Bases
facturer of custom mold
bases and specialty steels
• Mold Frames
for the plastics tooling • Precision Machining Services
industry, consisting of
• Stainless Steel
two main divisions that
service a diverse range • Tool Steel/Mold Steel
of customers.
edro.com

20 MoldMaking Technology July 2014

 TM

From left to right:

Unparalleled Commitment Perry Wilkes, West Regional Sales Mgr, EDRO
Todd Kuhn, Director-Tooling Technology, Tech Group
“EDRO’s commitment to supplying the best in tooling materials and Steve Patterson, Tooling Operations Mgr, Tech Group
machining services provides us with a complete solution for our custom Terry Henn, Vice President, EDRO
mold base and specialty tool steel requirements. This support combined
with our close relationship at all levels helps us to achieve our goals in
premium quality and customer satisfaction.”
Steve Patterson,
Tooling Operations Mgr
The Tech Group
A West Pharmaceutical Services Company EDRO Engineering and Specialty Steels, Inc.
Scottsdale, AZ Call: 1-800-368-EDRO
www.edro.com
TM
RoyAlloy Stainless is covered under Patents 6,045,633 and 6,358,334
Mold Materials Pages 19 to 30 Pg. 5

Ellwood Specialty Steel Phone: 724-657-1160

499 Honeybee Lane Fax: 724-654-9550
New Castle, PA 16105 Email: ESSsales@elwd.com

ess.elwd.com

PRODUCTS/SERVICES
Ellwood Specialty Steel is a U.S. based, fully integrated producer of tool
steels for plastic molds, die cast dies, forging dies and other tooling appli-
cations. ESS utilizes ASEA-SKF primary melting, refining and degassing
equipment along with ESR and VAR processes to manufacture premium
steel ingots. State-of-the-art forging, heat treating and machining equip-
ment is used in completing the tool steel manufacturing process to ISO
9001 standards. Ellwood Specialty Steel, the “Number One” choice in
North America for fast service and delivery, is backed by a 100-plus year
tradition of technical knowledge, unsurpassed product quality and the
highest level of customer service.

ESS is pleased to announce the addition of a specialty line of tool steels for
problem-solving applications in molds and dies. High thermal conductivity
Steels (HTCS), produced by Rovlama S.A., are rapidly gaining favor among
mold and die builders due to their ability to efficiently diffuse heat while
retaining the high strength, hardness and polishability of premium quality
mold steel. Several versions of HTCS are now in stock at ESS. Contact your
local ESS sales representative to discuss a solution to your design and oper-
ating challenges.

WEBSITE PRODUCT CATEGORIES

• Cold Work Die Steels
• Hot Work Die Steels
• Plastic Mold Steels

Review our full range of products by going to the products section

of the site, where you can get a brief overview of the product, as
well as view or download our comprehensive full-color brochures
(PDF Document). This Internet site is designed to give you 24-hour
access to the information you need the most.
ess.elwd.com

22 MoldMaking Technology July 2014

 We’re Focused on You.

While other suppliers turn their backs to supply

other hot markets, we’re stocking inventory,
investing, and servicing our customers 110%.
It’s been that way for the past 100 years and
will continue for the next 100 years. At ESS, we
always focus on our number one priority – you.
It’s what we do.

United States Canada

Ellwood Specialty Steel Ellwood Specialty Metals
800-932-2188 877-978-2772
esssales@elwd.com esmsales@elwd.com Ellwood Specialty Steel - Ready and Reliable.
Mold Materials Pages 19 to 30 Pg. 5

Bohler-Uddeholm Corporation Toll Free: 1-800-638-2520

2505 Millennium Drive E-mail: info@bucorp.com
Elgin, IL, 60124
bucorp.com

PRODUCTS/SERVICES

Uddeholm Mirrax 40 Uddeholm Caldie

The latest addition to our Stainless
Concept for plastic mold inserts, this
grade offers unique advantages to both
the mold maker and the user of the
mold. Readily machineable at 40 HRC,
remelted for high polishability, and
excellent corrosion resistance: this steel
is delivered prehardened. Use it for pro-
totype tooling (can be used into produc-
tion); plastic molds demanding a high
surface finish; molding of rubber and
corrosive plastics; blow molds; extrusion
dies; or even to move from a high hard
P20 to a stainless with similar or better
machinability.
The ideal grade when higher hardness
is required from an H13, S7 and A2,
this is our toughest steel at 58-62 HRC.
It is weldable, can be PVD coated and
nitrided safely with no movement, and
remelted making it suitable for molds
requiring the higher hardness and
polishability as well. Bohler K340 Isodur
Providing the wear resistance that a
thermoset plastic mold might need, this
8 percent Cr steel has the perfect bal-
ance between wear resistance and crack
resistance where D2 or M2 have been
used in the past for their hardness and
abrasive wear resistance.

WEBSITE PRODUCT CATEGORIES

Bohler-Uddeholm Corporation is the • Stainless Mold and Holder Steel
sales, marketing, and distributing
arm for our own mills: Uddeholms AB, • Tool Steel
Bohler, Villares Specialty Metals, and • High Speed Steel
Buderus. We have warehouses located
throughout the United States, including • Powder Metallurgical Stainless, Tool Steel, and
The Steel Store™ for cut pieces. High Speed steel
Headquartered in Elgin, IL, we carry a • Copper Beryllium Alloys
broad range of steels for mold making
requirements, along with advanced • Value Added Services
milling, grinding, and sawing capabilities.
• Technical Support
bucorp.com

24 MoldMaking Technology July 2014

The shortcut to perfect results
UDDEHOLM MIRRAX ® 40
Sometimes the most complicated problems have
very simple solutions. In the case of advanced mold
design, the solution is called Uddeholm Mirrax 40.
It’s a pre-hardened, electro slag remelted steel with
excellent machinability designed to drastically reduce
lead times for mold manufacture. It is the perfect
choice for corrosive and recycled plastics as well as
1.800.638.2520 | www.bucorp.com | Bohler Uddeholm Corporation | Elgin, IL 60124
complicated designs where heat treatment can cause
distortion or dimensional changes. Furthermore, with
Uddeholm Mirrax 40 and the other steel grades in our
Stainless Concept we can deliver stainless material for
every single mold component. Uddeholm Mirrax 40
lets you take a shortcut and still come out the winner.
For more information, please visit www.bucorp.com.
MATERIALIZING VISIONS
Mold Materials

e
Plat

er

te A per
s
ys

lloy
p
Ca s t
Allo

Cop

p
Sub ium Co
inum

inum

llium

st i tu
ll

s
Alum

Alum

Be r y

Be r y

Bras
COMPANY Advertisers are listed in bold type See Ad 1 2 3 4 5
Alcoa Inc., Cleveland, OH, 216-641-4162 1
Alpase, Chino, CA, 951-685-2155 1 2
Alro Steel Corporation, Jackson, MI, 517-787-5500 1 2 3 4 5
Ampco Metal Inc., Arlington Heights, IL, 847-437-6000 4
BMS Burns, Medina, OH, 800-345-7693
Bohler-Uddeholm Corporation, Elgin, IL, 630-883-3100 25 3 4
Clinton Aluminum and Stainless Steel, Clinton, OH, 330-882-6743 1 2
Copper and Brass Sales, Southfeld, MI 1 2 3 4 5
Diehl Steel Co., Cincinnati, OH, 513-242-8900
Dix Metals Inc., Huntington Beach, CA, 800-477-4349 1 2
DMS, Oldcastle, ON, 519-737-6743 1
Dow Corning Corporation, Midland, MI, 989-496-6000
Edro Engineering and Specialty Steels, Inc., Walnut, CA, 909-594-5751 21
Ellwood Specialty Steel, New Castle, PA, 724-657-1160 23 2
EOS of North America, Inc., Novi, MI, 248-306-0143 1
Finkl & Sons Co, A., Chicago, IL, 773-975-2510 1
General Plastics Manufacturing Co., Tacoma, WA, 253-473-5000
HASCO, Fletcher, NC, 828-650-2600 49
INDUSTEEL USA, LLC, Coatesville, PA, 610-383-3000
International Mold Steel Inc., Florence, KY, 859-342-6000
Ipsco International, Attleboro, MA, 508-226-1776 1
Materion Brush Performance Alloys, Mayfeld Heights, OH, 216-486-4200 3 4
Mold & Die Technology Inc., Traverse City, MI, 231-947-2341 5
National Bronze & Metals Inc., Houston, TX, 713-869-9600 3 4 5
Noren Products, Inc., Menlo Park, CA, 650-322-9500
OMNI Mold Systems, Lisbon, CT, 888-666-4755 Cov 3, 42
OnlineMetals.com, Seattle, WA, 206-285-8603 1 2 3 4 5
PCP Canada, Saguenay, QC, 418-677-3939 2
Performance Alloys & Services Inc., Germantown, WI, 262-255-6662 4
Rudolph Bros. & Co., Canal Winchester, OH, 800-375-0605
SCHMOLZ+BICKENBACH USA, INC., Carol Stream, IL, 630-682-3900 3
Smith Enterprises, Wood Dale, IL, 630-595-0202 3 4
Sorel Forge Co., Brampton, ON, 905-457-2501
Sturdell Industries, Rochester, NY, 585-464-0800
Superior Die Set Corporation, Oak Creek, WI, 414-764-4900 1
TCI Precision Metals, Gardena, CA, 800-234-5613 1 2 5
Tekcast Industries RI, Warwick, RI, 401-785-9500
Vista Metals Corp., Fontana, CA, 909-823-4278 1 2
Wacker Chemical Corp., Adrian, MI, 517-264-8500
Yarde Metals, Southington, CT, 860-406-6061 1 2

For more supplier listings, go to moldmakingtechnology.com/suppliers

26 MoldMaking Technology July 2014

 Mold Materials Pages 19 to 30

ers
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repo

ld S
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6 7 8 9 10 11 12 WEBSITE
alcoaqc10.com
alpase.com
6 7 10 11 12 alro.com
6 7 ampcometal.com
11 12 bmsburns.com
7 11 12 bucorp.com
11 clintonaluminum.com
6 7 11 tkmna.thyssenkrupp.com
11 12 diehlsteel.com
11 12 dixmetals.com
dmscomponents.com
8 9 dowcorning.com
11 12 edro.com
11 12 ess.elwd.com
6 eos.info
12 fnkl.com
8 generalplastics.com
11 12 hasco.com/gb
11 12 industeel.info
12 imsteel.com
11 ipscointernational.com
7 materion.com
moldshoptools.com
6 7 nbmmetals.com
7 11 norenproducts.com
11 12 omnimold.com
6 7 10 11 12 onlinemetals.com
pcp-canada.com
6 7 moldstar.com
8 9 10 rudolphbros.com
7 11 12 schmolz-bickenbach.us
11 smithpins.com
12 sorelforge.com
11 12 sturdell.com
12 superiordieset.com
7 12 tciprecision.com
9 10 tekcast.com
vistametals.com
9 wacker.com
11 yarde.com
Image courtesy of Creative Technology Corp.

moldmakingtechnology.com 27
Mold Materials
Copper Alloys Offer Thermal Conductivity, Strength
Materion Corp. offers a variety of high-strength copper alloys for full core
and cavity, core pins and hot runner components, including MoldMax, MoldMax
XL, MoldMax V and Protherm. With a combination of thermal conductivity and
strength, benefits of the alloys include shorter cycle time, improved plastic
part dimensional control, improved parting line maintenance, corrosion resis-
tance, machinability and wear resistance, Materion says.
Materion Brush Performance Alloys / 216-486-4200 /
materion.com
Self-Venting Mold Steel Used to Make Inserts, Pins
Molder’s World is a distributor of Porcerax II self-venting mold steel, and
offers a variety of Porcerax II parts and related services, including inserts and
Vortex core and press-in pins. In addition to design help and review, and manu-
facturing of Porcerax II inserts, the company provides related services such as
ultrasonic and high-pressure cleaning of the inserts; micro and ultrasonic pol-
ishing that won’t close pores or round sharp edges; and inspection and repair.
Molder’s World also is a distributor of Bio Corr Eco-Friendly Anti-Corrosion
Spray, which can be applied to molds without requiring removing before use.
The spray protects molds on the shelf for as many as 2 years and won’t clog
the pores of Porcerax II, the company says.
Molder’s World Inc. / 513-469-6653 / moldersworld.com
28 MoldMaking Technology July 2014
Aluminum, Stainless Alloy Varieties Available
With a motto of “the right alloy from the right application,” Clinton Aluminum
offers a variety of metals (with a focus on aluminum and stainless steel) and
works with customers to identify the ideal material for individual projects.
The company also cuts the metal closer to finished sizes for time and cost
savings. Its processing centers can handle material from 0.025” to 42” thick
and as long as 20 feet.
Clinton Aluminum and Stainless Steel / 800-826-3370 /
clintonaluminum.com
Specialty Steel Designed for Plastic, Rubber Molding
Edro Engineering’s RoyAlloy is a 400-series martensitic stainless steel
designed specifically for plastic and rubber molding applications. Supplied
prehardened to 321 Brinell, the grade is said to offer physical properties and
microstructures designed to provide reduced mold maintenance costs, safe
and simple weld repair, dimensional stability, and lower mold production costs
due to reduced cutting tool wear and increased cutting speeds.
According to the company, RoyAlloy offers excellent machinability and
weldability; good corrosion resistance and thermal conductivity; uniform and
consistent hardness; compressive strength; and dimensional stability.
The material is available in flat sizes as thick as 12” and rounds as large
as 12” in diameter.
Edro Engineering and Speciality Steels Inc. /
800-368-3376 / edro.com
Prehardened Steel Grade Suited for
Mold and Die
ExELL P-20 from Ellwood Specialty Steel is a Cr-Ni-Mo alloy tool steel
suited for a variety of mold and die applications, including injection
molds for thermoplastics, large compression molds, plastic extrusion and
film dies, blow molds, and zinc die cast dies. It is normally supplied pre-
hardened and can be surface-treated for additional surface performance.
Ellwood Specialty Steel / 800-932-2188 / ess.elwd.com

Aluminum Mold Plate Available
in Range of Sizes and Thicknesses
Duramold-2, Duramold-5 and Duramold-7 aluminum mold plate from Vista
Metals Corp. can be produced in thicknesses ranging from 1/4” to 38” and in
plate sizes as large as 94” x 200”. The company also offers ATP-5 precision
aluminum tooling plate, which is commonly used for base plates, jigs, fixtures,
machinery parts and backer plates for mold applications.
Vista Metals Corp. / 909-823-4278 / vistametals.com
Moldmaker Manufactures Plastic Injection Molds
Crest Mold Technology designs and manufactures a variety of plastic injec-
tion molds, including standard two-plate, three-plate, hot runner, multi-cavity,
prototype, insert, gas-assist and two-shot. The company’s molds are used in
a range of applications and industries, including instrument panels, restraint
systems and interior panels in automotive; telephone bodies, receivers and fax
machine components in telecommunications; disposal system components in
recreational vehicles; copier and computer components in electronics; contact
lens containers in medical; thermostat panels in HVAC; model trains in toys;
water purification systems and plumbing fixtures in household goods; and
plastic bullets for the U.S. Department of Defense.
Crest Mold Technology Inc. / 519-737-1546 / crestmold.com
Aluminum Cast Materials Used in Molds
Alpase produces M-1, M-5 and K100-S aluminum cast products.
M-1 and M-5 mold plate is used in blow molding, injection, compression,
RIM and rotational tools, as well as heavy- and thin-gauge vacuum form tools.
According to the company, M-1 and M-5 materials are widely preferred and
specified in the semiconductor market, and offer excellent machinability and
stability along with very high thermal conductivity.
K100-S cast tooling plate features a micro-sheen finish and is said to
offer excellent thickness tolerances and guaranteed flatness before and
after machining. This material is said to provide vacuum integrity, improved
mechanical properties and superior corrosion resistance.
Alpase / 951-685-2155 / alpase.com
Mold Materials Pages 19 to 30
High Hard Mold Steel Well-Suited for
Large Plastic Molds
Diehl Steel’s P-20 high hard mold steel is a prehardened, uniform and “clean”
product that can be polished to an extremely high finish, making it well-suited
for plastic molding applications, injection molds, compression molds, mold
frames, forming tools and die holders. It is available in flats, hollow-bar, met-
ric, non-standard, rounds, squares and standard forms.
According to the company, P-20 is tested to rigorous tool steel standards to
ensure uniformity of structure and freedom from defects. It exhibits excellent
compressive strength, and its balanced alloy composition ensures uniform
cross-sectional hardness.
Diehl Steel also offers a variety of grades of CPM powder metal tool
steel, including CPM 1V, a medium-carbon steel that exhibits high impact
toughness; CPM 3V, an air-hardening powder metal steel that offers both
high impact toughness and wear resistance; CPM 9V, which also offers high
wear resistance and impact toughness; CPM 10V, an air-hardening, powder
metal tool and die; CPM 15V, a powder metal tool steel with exceptional wear
resistance; CPM REX M-4, a powder metal steel that offers improved cutting
tool life; CPM REX 76, a super-high-speed steel that contains high carbon,
vanadium and cobalt for abrasion resistance; CPM REX T15, a tungsten-type
super-high-speed-steel that contains high vanadium for abrasion resistance;
and CPM REX 45, an 8-percent cobalt super-high-speed steel with excellent
hot hardness.
Diehl Steel Co. / 513-242-8900 / diehlsteel.com
Beryllium-Free Materials Offer
High Thermal Conductivity
Well-suited as a replacement for beryllium copper, AMPCO Metal’s
beryllium-free AMPCOloy944 mold material has a hardness of 31 HRc
and a thermal conductivity of 156 W/m.K. For applications that require
higher thermal conductivity to 208 W/m.K and with a hardness of HRb
95, the company offers AMPCOloy940. Both materials are available
in the United States, Europe, India and China as forged plates and
extruded rounds.
AMPCO Metal Inc. / 800-844-6008 / ampcometal.com
moldmakingtechnology.com 29
Mold Materials
Considerations for Mold
Base Material Selection
By Paul Britton
Choosing the right mold base material can greatly affect the
profitability and cost of your application. There are three
general material categories to consider: hot-rolled steel,
chrome-moly materials and stainless steel.
Hot-rolled steel materials vary from low-carbon (A-36 or
1020) to medium-carbon (1045 or 1050). These steels are easy
to machine and have reasonable tensile strength. They also
are easy to find and are very cost-friendly. Hot-rolled steels
are usually chosen when there are very low production runs
associated with the project.
Chrome-moly materials include 4130, P20, 4140, etc. They
have a hardness range from 28 to 34 HRc and offer good
mechanical properties. These materials are ideal for cavity
and core plates as well as other plates required in the mold
base. They can be machined fairly well, but stress relief may
be required with heavy machining or grinding.
Stainless steel (a modified 420 F material that is used for
holder block applications) is pre-hardened to 30-35 HRc. It
offers good corrosion resistance and machinability, is very
stable, and does not require stress relief. In applications
where humidity is a problem or corrosive material is being
used, stainless steel works well.
LEARN MORE
Visit our Mold Materials Zone for more information about tool
steel, aluminum, copper and alloys.
Go to moldmakingtechnology.com/zones for a complete list.
In addition to these three traditional categories, today
there are two additional mold base materials to consider.
The first falls in the stainless steel category as an improved
420 F material currently competing with 1.2085 in Europe. It
features excellent machining qualities and does not require
stress relief. By lowering the carbon and chrome content, this
material offers improved machinability, and 10 to 15 percent
better thermal conductivity than the 420 F material.
Keep in mind that having an advantage with regards to
thermal conductivity depends on how large the part is as well
as the number of cavities involved. Customers are always try-
ing to find ways to lower cycle time and this is one way to
help lower that value.
30 MoldMaking Technology July 2014
Mold Materials Pages 19 to 30
Image courtesy of International Mold Steel Inc.
Today, there are two other mold base materials to consider in addition to
hot-rolled steel, chrome-moly material and stainless steel materials.
This stainless steel material also benefits from tightened
rolling tolerances, which means a mill can deliver higher-
dimensional-quality-steel to the end user, saving time and
money. For example, the leading stainless material currently
requires around 6 mm oversizing to finish to the desired
dimension. The improved rolling capabilities of the newer
material can reduce the amount of oversize needed by 20 to
33 percent, lowering costs for customers. The mill can roll
material as thick as 5.5 inches and as wide as 96 inches.
The second additional mold base material is a P20-type
that offers improved machinability and stability, even dur-
ing heavy machining and grinding, and also does not require
stress relief. It also makes gundrilling much easier due to
the absence of hard spots. This material possesses a unique
chemistry and is supplied in 30-35 HRc. It comes off the roll-
ing mill and immediately receives a fast-quench heat treat-
ment that differs from the heat treatment applied to other
quench and tempered steels. There is no tempering process
with this material.
When looking to decrease costs and improve the profit-
ability of your next job, don’t forget to consider the impact
of your mold base material selection.
CONTRIBUTOR
Paul Britton is national sales manager for International Mold Steel Inc.
FOR MORE INFORMATION:
International Mold Steel Inc. / 859-342-6000
800-625-6653 / britt@imsteel.com / imsteel.com
 Pages 31 to 38

Hot Runners
Pages xxx to xxx

Image courtesy of Mold Design Inc.

moldmakingtechnology.com 31
Hot Runners Pages 31 to Pg.
38 5 to 9

INCOE® Corporation Phone: 248-616-0220

1740 E. Maple Road Fax: 248-616-0227
Troy, MI 48083
incoe.com

PRODUCTS/SERVICES
Founded in 1958, INCOE® is a global company that is 100% family owned and operated. Our com-
mitment to supporting the plastics industry, innovating new hot runner solutions and providing
“best-in-class” service to customers is our priority. As a pioneer in the plastics industry, INCOE®’s
original patented hot runner nozzle was the first commercially available. By design, the hot runner
system has been cost effective and “eco-friendly” since inception with reduced material use and
waste by-product.

DIRECT-FLO™ Gold hot runner systems offer proven performance advantages, reliability and cost
effectiveness in the most demanding applications. Features include custom and standard system
configurations, non-valve and valve gate systems, mold flow analysis and exclusive OPTI-FLO®
manifold systems; all designed to reduce cycle times with improved part quality.

UNITIZED LEAK-PROOF systems have over a decade of use globally in a wide range of applications.
Customers have benefitted from the added value of our “Ready-to-Connect” system with simplified
integration and quick start-ups. Add in our Leak-Proof design for maximum productivity, and you
have an unbeatable combination.

SOFTGATE® Valve Pin Velocity Control systems resolve issues related to conventional hydraulic
sequential molding. The key advantage for molders is in the gradual pin actuation, precisely timed
as needed for optimized melt flow. The results are significant reductions in cosmetic blemishes and
weld lines, with improved part-to-part consistency.

Whether you’re molding commodity grade or highly engineered resins, INCOE® has the depth of
application and processing experience to drive your business. Localized support where and when
you need it, ensures you are running at top speed in a competitive global marketplace.

NEW WEBSITE PRODUCT CATEGORIES

• Hot Runner Systems for Micro to
Large Part Applications
• Thermal Tip, Sprue and Valve Gate Designs
• Temperature, Sequential and Valve
Gate Controls
• Complete Hot Half Systems
• Single Nozzle Systems
The multi language website is a resource and information tool for
• Stack Mold Systems
customers in any market. Features include product search, RFQ’s,
videos and an array of product guides, manuals and brochures in • Screen Pac Melt Filtration
PDF format for easy download. • IMN (Injection Machine Nozzle)
incoe.com

32 MoldMaking Technology July 2014

 We’re everywhere.

Since 1958, INCOE has focused on providing the plastics industry with innovative hot runner
systems, creative solutions and first-in-class customer service and support. Why? Because, we
believe our role is in ensuring our customers are competitive in markets throughout the world.
Our team of professionals are experienced, knowledgeable and dedicated. Don’t leave your
molding solutions to just anyone. Look to INCOE... we’re tried, tested and true.

INCOE Corporation - Global Headquarters

1740 East Maple Road
Troy, Michigan 48083 USA
T +1.248.616.0220
F +1.248.616.0225
E info@incoe.com

Expertise you can trust. Technology you can rely on.

North America | Europe | Asia | South America
www.incoe.com
© 2014 INCOE® is a registered trademark of INCOE Corporation, USA and in other countries
Hot Runners

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COMPANY Advertisers are listed in bold type See Ad 1 2 3 4 5
Alba Enterprises Inc., Rancho Cucamonga, CA, 909-941-0600 1 3 4 5
Ampco Metal Inc., Arlington Heights, IL, 847-437-6000 3 5
Athena Controls, Plymouth Meeting, PA, 610-828-2490
Blue Wave Ultrasonics, Inc., Davenport, IA, 563-322-0144 2
Chem-Trend L.P., Howell, MI, 517-546-7980 2
Cold Jet, LLC, Loveland, OH, 513-831-3211 2
Dalton Electric Heating Co., Inc., Ipswich, MA, 978-356-9844 3
DME Company, Madison Heights, MI, 248-398-6000 47 1 3 4 5
DMS, Oldcastle, ON, 519-737-6743 3
Ewikon Molding Technologies, Inc., Rockford, IL, 815-874-7270 1 2 3 4 5
Extrude Hone Coporation, Irwin, PA, 724-863-5900 2 4
Fast Heat Inc., Elmhurst, IL, 630-359-6300 3
Gammafux, Sterling, VA, 703-471-5050 3
Gunther Hot Runner Systems Inc., Hoffman Estates, IL, 630-293-4650 1 3 4 5
HASCO, Fletcher, NC, 828-650-2600 49 1 3 4 5
Hotset America Corp., Swainsboro, GA, 912-289-1844 3 4
HRS Flow North America, Windsor, ON, 519-973-0212 37 1 2 3 4 5
Husky Injection Molding Systems, Milton, VT, 802-859-8000 1 2 3 4 5
IMS Company: Industrial Molding Supplies, Chagrin Falls, OH, 440-543-1615 3
Incoe Corporation, Troy, MI, 248-616-0220 33 1 2 3 4 5
J-Tech Hotrunner Inc., Caledon, ON, 519-927-1067 1 3 4 5
Mastip, Inc., Slinger, WI, 262-644-9400 1 3 4 5
Melt Design Inc., St. Charles, IL, 630-443-4000 1 2 3 4
MHS - Mold Hotrunner Solutions, Georgetown, ON, 905-873-1954 1 3 4 5
Mold-Masters Limited, Georgetown, ON, 905-877-0185 1 2 3 4 5
Molders Choice Inc., Parma, OH, 216-458-1220 3
OSCO Inc. Runnerless Molding Systems, Rochester Hills, MI, 248-852-7310 1 3 4 5
PCS Company, Fraser, MI, 586-294-7780 Insert, 45 1 3 4
Plastic Engineering & Technical Services, Auburn Hills, MI, 248-373-0800 1 2 3 4 5
Plastic Process Equipment, Inc., Macedonia, OH, 216-367-7000 3
Polymer Cleaning Technology, Inc., Hillsborough, NJ, 908-281-0055 2 3
Polyshot Corporation, West Henrietta, NY, 585-292-5010 1 2 3 4 5
PRIAMUS System Technologies, LLC, Brunswick, OH, 877-774-2687
PSG Plastic Service Group, Inc., Stevensville, MI, 269-556-7051 1 3 4 5
StackTeck Systems Limited, Brampton, ON, 416-749-1698 3 4
Synventive Molding Solutions, Peabody, MA, 978-750-8065 1 3 4 5
Tempco Electric Heater Corp., Wood Dale, IL, 630-350-2252
Thermal-Tech Systems, Inc., West Chicago, IL, 630-639-5115 1 2 3
Thermoplay S.P.A., Pont Saint Martin (AO), 39 125 800311 1 3 4 5
Watlow, St. Louis, MO, 314-878-4600 3

For more supplier listings, go to moldmakingtechnology.com/suppliers

34 MoldMaking Technology July 2014

 Hot Runners Pages
Pages315toto38
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6 7 8 9 10 11 12 13 WEBSITE
6 7 8 9 10 11 12 13 albaent.com
7 10 ampcometal.com
8 hotrunnercontrol.com
bluewaveinc.com
chemtrend.com
coldjet.com
8 daltonelectric.com
7 8 9 10 11 12 13 dme.net
dmscomponents.com
7 8 9 10 11 ewikonusa.com
extrudehone.com
8 fastheat.com
8 12 gammafux.com
6 7 8 9 10 11 12 gunther-usa.com
8 9 10 11 hasco.com/gb
8 12 hotset-worldwide.com
7 8 10 12 13 hrsfow.com
6 7 8 9 10 11 12 13 husky.ca
8 imscompany.com
7 8 9 10 11 12 13 incoe.com
6 7 8 9 10 11 12 13 jtechhotrunner.com
7 8 9 10 11 mastip.com
7 8 9 10 11 meltdesign.com
6 7 8 9 10 11 12 13 mhs-hotrunners.com
6 7 8 9 10 11 13 moldmasters.com
8 molderschoice.com
6 7 8 10 11 12 13 oscosystems.com
8 12 pcs-company.com
6 7 8 9 10 11 12 13 petsinc.net
8 ppe.com
polymercleaning.com
6 7 8 9 10 11 12 13 polyshot.com
8 12 13 priamus.com
6 7 8 9 10 11 psg-online.de/en/home
stackteck.com
7 8 10 11 12 13 synventive.com
8 tempco.com
thermal-tech.com
7 8 12 13 thermoplay.com
8 10 watlow.com
Image courtesy of Husky.

moldmakingtechnology.com 35
MoldRunners
Hot Materials
Injection Unit Adds Multi-Shot Capability to
Single-Material Molding Machines
Mold-Masters has added two models, the EM4 and EM2, to its E-Multi line
of portable auxiliary injection units that are designed to easily convert a
single-material press into a multi-material system. The units are said to be
especially suited for molders looking to economically optimize their existing
injection molding machines. The mold-mounted, servo-driven injection units
are portable and compact, and can add multi-shot capability to virtually any
standard molding machine.
A radial mounting option also is available that allows the injection unit to
swing to the non-operator side for mold changes and positioning flexibility.
Mold-Masters / 905-877-0185 / moldmasters.com
Valve Gate System Enables
Pin Adjustment in Large Applications
The FlexFlow electrical valve gate system from INglass’ HRSflow
division enables precise adjustment of the position, velocity and
stroke of the valve pin for large vehicle applications such as fend-
ers, dashboards, doors and other large components that require
sequential molding.
The valve gate also is well-suited for production of optical parts
that require high aesthetic standards. It is designed to eliminate
common defects such as flow marks, knit lines and burrs on injec-
tion points. The FlexFlow control unit allows the operator to control
the filling pressure by controlling valve pin opening speed and
stroke, thereby reducing pressure drops.
HRSflow / 855-477-3569 / hrsflow.com
INglass / 39 0422 750 111 / inglass.it
36 MoldMaking Technology July 2014
System Offers Two-Speed
Sequential Valve Gating
SynFlow from Synventive Molding Solutions is a two-speed
pin control technology for sequential valve-gated hot runner
systems, designed to provide optimized plastic flow control
and solve common surface defect problems on large parts
such as automotive bumpers and instrument panels.
The initial opening speed of the valve pin is reduced to
prevent an explosive rush of pressurized plastic. The valve
pin then opens for the remainder of its stroke at maximum
speed to appropriately fill the part. This process enables a
smooth fill, reducing hesitations and sharp velocity changes.
This results in in cleaner parts with improved surface quality,
and improved process efficiency, the company says.
Synventive Molding Solutions / 978-750-8065 /
synventive.com
Injection Molding Nozzles Offer Low Pressure Losses
HMM Solutions offers a variety of components for mold and injection molding
machines, including a selection of nozzles.
The MSF machine nozzle features a gap filter design that is said to offer a
greater flow area than screen-pack designs, resulting in lower pressure drops.
The gap size is determined by the height of the ribs relative to the nozzle’s ID
and can be increased by cylindrical grinding. The nozzle is available with gap
sizes ranging from 0.1 to 1.2 mm.
The ES-2 purgeable nozzle and MF-200 mixing nozzle are both low-pressure
systems in which filtration size can be customized to specifications. Large
filtration passageways ensure low pressure losses. The ES-2 can be used with
reinforced materials and is designed to be easily cleaned by unscrewing the
2-5-mm (0.08"-0.20") #2 nozzle tip and then slowly purging the machine bar-
rel. Recommended for frequent color changes, the MF-200 offers fast, double-
action color mixing. At the end of one color run, the first mixing nozzle filter
can be removed and cleaned while the second nozzle is installed and run. The
nozzles may be cleaned ultrasonically.
The company’s NM shut-off nozzle is designed to minimize drool and save
material and service maintenance. Operation is completely automatic; injec-
tion pressure causes the shut-off needle to open and allow plastic melt to flow
freely. As soon as injection pressure is decreased below a specified pressure,
a high-temperature Inconell spring pushes the needle into the closed position,
shutting off the flow of plastic. The opening pressure can be customized, and
the NM can be flushed clean while on the barrel.
HMM Solutions Inc. / 719-221-6444 / hmmsolutionsinc.com

Additional Lengths Added to Nozzle Series
Hasco has added 100- and 125-mm lengths to its Size 20 Technic Shot nozzle
series. The Type 20 is designed for small shot weights and, with its compact
external dimensions, for small cavity-to-cavity distances. In addition, the
combination of nozzle body, sleeve, torpedo, thermocouple and heating unit
ensures easy handling during maintenance. The heating unit can be removed
from the nozzle body, for example, without having to undo the gate. The
thermocouples and nozzle heating are separate units which can be replaced
independently of each other.
According to the company, the two additional nozzle lengths allow even
greater immersion depths in injection molds. In addition, a front-mounted
nozzle heater is now available for these nozzle lengths, easing hot half
maintenance.
Hasco / 877-427-2662 / hasco.com
Nozzles Offer Better
Edge Gating for Medical Products
Available from Technoject Machinery
Corp., Heitec’s Star-Line Crown radial and
linear nozzles feature edge gating and offer no
splitting of cavity inserts and no visible parting
line at the part. The nozzles are available with as
many as 12 tips and are well-suited for small cavity
spacing and long, thin-walled articles.
Gate diameters starting at 0.4 mm are available. Tip
replacement and cleaning is completed at the machine.
According to Heitec, maximum precision and repeat-
ability is achieved through thermal and rheological
balancing. The nozzles also offer energy savings due to
increased cavitation with fewer nozzle drops.
Particularly suited for the medical industry, molding
applications include syringe barrels and plungers, pipettes, spray caps, gen-
eral caps and closures, connectors, tubes and sleeves, and housings.
Technoject Machinery Corp. / 905-951-7144 / technoject.com
HotHotRunners
Runners Pages
Pages315toto38
11
Hot Runner Controller
Covers as Many as 128 Zones
Husky Injection Molding Systems has added to its family
of Altanium hot runner temperature controllers. The Altanium
Delta3 is designed to bridge the gap between the functional-
ity of the company’s Neo2 and Matrix controllers, offering an
integrated, intelligent platform for two to 128 zones of control
for increased part quality and improved uptime.
Delta3 features a variety of enhancements for improved
operational efficiency, including a highly intuitive naviga-
tion method coupled with a large, full-color touchscreen;
automatic storage and recall of setups; multilingual sup-
port; and historical event auditing and enhanced process
monitoring for faster, more accurate troubleshooting.
An integrated control card is designed to maximize
system reliability by minimizing discrete connec-
tions and components. All Altanium controllers also
use Husky’s Active Reasoning Technology (ART) for greater shot-to-shot and
cavity-to-cavity consistency and repeatability. ART is said to deliver tighter
control and minimized variability through best-in-class power output delivery,
fully isolated thermocouple inputs and high thermocouple sample rates that
ensure the integrity of temperature readings.
Husky Injection Molding Systems / 802-859-8000 / husky.ca
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moldmakingtechnology.com 37
MoldRunners
Hot Materials Hot Runners Pages 31 to 38

Hot Runner
Design Evaluation

By Sal Benenati

Images courtesy of Orycon Hot Runner Systems.

One way to avoid potential problems is to evaluate the design
of a hot runner system in a critical but constructive way.
Here are three basic hot runner design considerations:
1. Purity. Although innovation in design is very important,
you need to consider its positive and negative effects on
your specific application. A good rule of thumb is to keep it
simple and direct. For example, use a direct approach to keep
the manifold and nozzles at the desired temperature, and
the plastic material flowing evenly. Over-simplified or over-
designed system features could be signs of potential prob-
lems. The system’s design should have everything it needs
and nothing more. These valve-gated nozzles are designed with replaceable components
(including pins) that do not require hot half disassembly.
Possible red flags may include belabored heater design,
heaters wound too tight, heaters with low contact area,
heaters with wattage that is much higher or lower than heated, they can expand enough to damage the cavity or
comparable systems, the use of exotic metals, components/ system. While the main objective is always system perfor-
manifolds that are too thick or too thin, and features that mance, the hot runner design should also help reduce the
appear unnecessary. probability of a system failure.
Let’s take a closer look at the use of exotic materials in hot 3. Ease of maintenance. Remember that someone has to
runner component design. For example, nozzle tip shut-off work on it. Most hot runner systems are great when they
rings made of titanium. At the design stage, titanium’s high work as intended, however, no system will work indefinitely
strength and low heat transfer rate may make it more desir- without requiring some attention and maintenance. A seem-
able for the component than tool or stainless steel. However, ingly unimportant component can stop working, and if not
the fact that titanium facilitates steam condensation might detected and addressed immediately, a small problem can
be overlooked. Moisture (due to weather or mold-cooling quickly transform itself into a catastrophic failure.
temperatures) can get into the manifold housing and con- A good way to reduce this probability is to reduce the
dense around the tip’s shut-off area, remaining there at tem- number of parts in the system. Not an easy task to accomplish,
peratures close to boiling point. Rust and corrosion can then but easy enough to notice during system evaluation. Easy
develop within the highly precise fit area, and if the mold accessibility to components and wiring is one of the most
cavity is not made of stainless, the plastic can start to seep desirable hot runner assembly features, as is a design that
into the manifold-retaining cavity. allows nozzle heater and thermocouple replacement from the
2. Practicality. The hot runner system should be easy to front of the plates without disassembly of the hot half.
assemble into the molds without requiring special tolerances
or tools. It should be responsive to the controls and able to
CONTRIBUTOR
maintain a stable processing temperature window that is
Sal Benenati is chief operating offcer of Orycon Hot Runner Systems. He has
close to the resin manufacturer’s specifications without using been awarded several patents over the past 30 years for controller, manifold
special controls or critical settings. and nozzle innovations.
You can find tolerance requirements in the manufac-
turer’s system specifications or literature, but you also need
to ensure that there are no tolerance restrictions in nozzle FOR MORE INFORMATION:
lengths. In addition, some systems shut off at the front of Orycon Hot Runner Systems
the nozzles, which means that the nozzles must be kept at a 732-922-2400 / sal@orycon.com / orycon.com
precise temperature while in operation. If they become over-

38 MoldMaking Technology July 2014

COME
TOGETHER.
MICHELLE DOWNING
Procurement
Miba Bearings US, LLC

YEARS ATTENDING IMTS

3

GOAL FOR IMTS 2014

I look forward to seeing frsthand what
emerging technologies are available for
the manufacturing sector, and bringing
that information back to my own facility.
What I learn at IMTS often leads to
improvements on a local level, but it also
helps me bring quality information back
to our global sites.

LEAVE
INFORMED.

Where else can you meet the minds that are moving manufacturing
forward? Nowhere but IMTS 2014. With a focus on success through
cooperation, the week will be flled with technology, education, and
ideas that we can all beneft from. Join us at McCormick Place Chicago,
September 8–13, 2014. Learn more at IMTS.com.
COME TOGETHER.
EARLY BIRD PRICING ENDS AUGUST 8 • IMTS.COM LEAVE YOUR MARK.
 Search Machines Smarter.

Spindle: Milling

Direction: V or H
# of Main Spindles: Envelope:
Max. HP:
Max. Table Length:
Top RPM:
Max. Table Width:
Max. Part Weight:

Machine Type:

Machining Center

Drill/Tap

Boring Mill

Milling Machine
PHOTO: Hwacheon

A Gardner Business Media Metalworking Group Product

The Machine Tool Search Engine

techspex.com
 Pages 41 to 60

Mold Components
Pages xxx to xxx

Image courtesy of Aalbers Tool and Mold.

moldmakingtechnology.com 41
Mold Components
PRODUCTS/SERVICES
Versa-Slide Faces
OMNI Mold Systems LLC has added
“slide faces” for many of its very popular
Versa-Slides®. This addition adds even
more time savings to an already great
product line. Moldmakers no longer
need to make the face or retainer plate
for our slides. All slide assemblies from
the smallest SL-10-10 to the mid range
SL-40-90 now have a matching slide face
available for shipping “off the shelf.” For
the very small 10 and 20 Series Versa-
Slides,® we have selected P-20 material
and we have finish machined the slide
face complete. Just cut to the proper
length and add your geometry. For the
25 through 40 Series Versa-Slides® we
have selected H-13 (soft) material and
left 0.005 grind stock on all sides.
WEBSITE
No more pushing your supplier for better leadtimes. No more
wondering what the mold base will cost you. No more worrying
about scrapping a mold plate or slide component.
omnimold.com
42 MoldMaking Technology July 2014
OMNI Mold Systems LLC
21 Kimball Heights Lane
Lisbon, CT 06351
New Versa-Slides
OMNI Mold Systems LLC has expanded
its Versa-Slide product line to include
the new SL-45 & SL-55 Series of standard
slide units. The new sizes (5.250” and
8.000” wide) have been added to fill
gaps in the existing product line. These
new additional sizes bring the total “off
the shelf” offering to 68 standard assem-
bly numbers with any number of possible
“modified” units by mixing and matching
components. OMNI Versa-Slides, widely
accepted as the “industry standard” off-
the-shelf slide assemblies, have been
running successfully in plastic injection
molds for over 12 yrs. The company also
offers a free layout service to show your
parts in our standard mold bases (where
applicable) and can help you decide which
slides will work best with your project.
PRODUCT CATEGORIES
• Lifters
• Mold Alignment Products
• Mold Bases
• Mold Frames
• Parting Line Side Locks
• Slides
• Stainless Steel
• Tool Steel/Mold Steel
Pages 41 to 60
Toll Free Phone: 888-666-4755
Toll Free Fax: 888-816-2850
omnimold.com
Custom Mold Bases
OMNI Mold Systems LLC has formed a
working partnership with Target
Precision, a custom mold base manufac-
turer in Harmonsburg, PA. The partner-
ship allows OMNI to offer full custom
mold bases to all of its customers for
the first time. Through the partner-
ship, Target Precision is able to offer all
OMNI Mold Systems standardized prod-
ucts from mold bases to sucker pins.
This partnership expands the capacities
of both companies. For the first time in
its history, OMNI can now supply
fully custom designed mold bases with
Target’s manufacturing expertise and
machining capacity.
Mold Components Pages 41 to 60

Progressive Components Toll Free: 800-269-6653

235 Industrial Drive Phone: 847-487-1000
Fax: 800-462-6653
Wauconda, IL 60084
procomps.com

PRODUCTS/SERVICES

Z-Series Bar Locks Standard Wear Plates Mold Monitoring Advancements

Z-Series Bar Locks give mold designers
a standard, off-the-shelf solution for
alignment of large molds and multi-plate
sequencing tools, delivering the maximum
amount of guidance and support for the
minimum amount of machining required.
Featuring Z-Series proprietary treat-
ments, engagement ramp geometry and
particle rings on the guiding surfaces,
Bar Locks provide long-term precision
alignment of plates as well as long-lasting
durability and wear resistance.
Bar Locks are available in 4 standard
widths and lengths up to 16" long.
Customs are also available.
New, standard Wear Plates feature
exclusive Z-Series particle rings and
material treatments, making them the
answer for mold builders seeking supe-
rior wear resistance and convenience
versus manufacturing them in-house.
Their thin profile, at only ¼" thick,
allows more room for waterlines or
other mold features. Wear plates are
available in 14 sizes, starting as small as
.500" x. 500" with verified 2D and 3D
geometry for designers’ convenience.
Multiple pads can be used where large
areas require a wear surface. Custom
sizes can also be provided.
CVe Monitor®, v2, with CVe Live®,
provides unmatched tooling visibility.
CVe Monitor advancements include:
• PM Alerts and Device Removal Monitoring
• Three mounting options available
• 4GB flash drive for increased file storage
• OnDemand software upgrade enables
use of new CVe functions in 10 languages.
CVe Live, a hardware/cloud platform,
provides OEMs and molders with secure
access to current mold activity reports
from the CVe Monitor via Press Modules
and Gateway Hardware. Its dashboard
gives users information at a glance or one
can drill into specifics on each tool.

WEBSITE PRODUCT CATEGORIES

• Mold Components
• Mold Maintenance, Repair & Surface Treatment
• Services
• Software

Progressive Components features off-the-shelf standards designed

to speed mold building and reduce costs and downtime.
Products are provided throughout a network of locations
including regional hubs in England and Singapore.
procomps.com

moldmakingtechnology.com 43
Mold Components Pages 41 to 60

PCS Company Phone: 800-521-0546

34488 Doreka Drive Fax: 800-505-3299
Fraser, MI 48026
pcs-company.com
buyatpcs.com

PRODUCTS/SERVICES

Mold Bases Mold Maintenance Products Pins & Components

PCS Company offers a full line of
standard, off the shelf P20 mold bases.
Our standard P20 offering includes
thirty one different frame sizes and nine
different A & B plate thicknesses. In
addition to the P20 offering, we offer
stainless steel, aluminum, and custom
mold bases. Our Fast Interchangeable
Tooling (F.I.T.S™) units allow for quick
tool changeovers, dramatically reducing
downtime.
PCS company’s High Performance Mold
Maintenance Products are designed
to work as an integrated family with
the sole purpose of making the plastic
injection molding process more efficient.
This family of products include mold
release coatings, grease, cleaners/
degreasers, and rust preventatives.
Together these products will help your
mold run more efficiently.
Pins and molding components have been
a staple of PCS company’s business for
over 50 years. We offer a full line of pins,
blades, sleeves, various bushings and
much more. Our Hardened Throughout™
ejector pins are manufactured right here
in the U.S.A. From ejector pins to limit
switches, PCS is stocked to support all
your tooling needs.

WEBSITE PRODUCT CATEGORIES

• Standard & Special Mold bases
• High Performance Mold Maintenance Products
• Pins & Components
• Custom Components
• Hot Runners Systems

Visit www.pcs-company.com to find information on products

and promotions. Downloadable pricelists, brochures, and CAD
files are also available. Check out the discontinued and over-
stock section at www.buyatpcs.com for additional savings!
pcs-company.com

44 MoldMaking Technology July 2014

 Finish Ground
Blank Mold Plate
P20 & Stainless Steel
Over 250 Frame Size and Plate Thickness Combinations
Two new
Features: sizes addframe
ed!
• Off the shelf availability 15-7/8”
• Plate thickness range: 7/8” - 5-7/8” x 26”
&
• Frame sizes: 8” x 8” - 24” x 29” 17-7/8”
• Finish ground +/-.001” x 26”
• P20 (#3) steel pre-heat treated 280-320 BHN/28-34 HRC
• Stainless Steel pre-heat treated 300-340 BHN/32-36 HRC

Phone: 800-521-0546 www.pcs-company.com E-mail: sales@pcs-company.com Fax: 800-505-3299

Mold Components Pages 41 to 60

DME Company Toll-free (U.S. only): 800-626-6653

29111 Stephenson Highway Worldwide: 248-398-6000
Madison Heights, MI 48071 Fax: 888-808-4363

dme.net

PRODUCTS/SERVICES

Molding Undercuts Metric Components Large Mold Base

Featuring a wide range of undercut
molding options, DME is the go-to
solution for any application. The Dove
Tail Collapsible Core provides solutions
for hard-to-mold internal undercut
features such as o-ring grooves, slots
and snap fit details. The VectorForm
Lifter System provides mold design
flexibility by allowing for molding
undercuts twice as deep as previously
possible due to accommodation of
angles over 30 degrees. You’ll benefit
from reduced design, installation time
and maintenance.
For all the high-quality mold compo-
nents you need, DME is your essential
resource. So when we heard your call
for more metric-standard products, we
didn’t hesitate to deliver for you—by
building up the largest inventory of
metric ejector pins, sleeves and blades.
DME now offers same-day shipments on
our comprehensive line of DIN and JIS
ejector pins, sleeves and blades.
• Hardened
• Nitrided
• Special applications
• All the sizes you need
Now you can get large, precision bases—
with plates up to 66 inches long, 54 wide
and 13 thick—from DME, the standard
setter in mold base quality since 1942.
Utilizing new leading edge machining
equipment technology, all three DME
North American manufacturing centers
now produce large mold bases more rap-
idly and with greater quality than ever
before. So you can count on the quality
you need from us, while focusing on the
profitable finish work you do best.

WEBSITE PRODUCT CATEGORIES

DME, an essential resource to
the plastics industry, offers the
broadest range of market-leading
products, unsurpassed knowledge
and expertise, and a global logistics
infrastructure that ensures speed
and accuracy. Now with easy online
ordering, visit our website for all
your needs.
dme.net
• Mold Bases & Plates
• Mold Components
• Hot Runner Systems
• Quick-Change Mold Systems
• Control Systems
• Moldmaking Equipment & Supplies
• Technical Services
• Mold Repair and Refurbishing
• Molding & Industrial Supplies

46 MoldMaking Technology July 2014

GO BIG .
LARGE MOLD BASES
N O W S TA N D A R D F R O M D M E

Now you can get large, precision bases – with plates up to 66 inches long, 54 wide
and 13 thick – from DME, the standard setter in mold base quality since 1942. So
you can count on the quality you need from us, while focusing on the proftable fnish
work you do best.

Discover more at
www.dme.net/largemoldbases
Mold Components Pages 41 to 60

HASCO America, Inc. Phone: 877-427-2662

270 Rutledge Rd. Unit B Fax: 828-684-7960
Fletcher, NC 28732
hasco.com

PRODUCTS/SERVICES

Z99/…Z9901/… HASCO
CoolCross
It’s now possible to have cooling channels
crossing each on the same plane in a flex-
ible and inexpensive manner so water can
cross in two separate directions. CoolCross
permits even temperature distribution
in cores or inserts and constant cavity
cooling on all four sides for the duration
of the injection molding cycle. The Z
99/… allows the number of cooling
channels to be reduced to a single plane.
Permitting thinner plates and other
accessory components.
A8001 HASCO Clamping Fixture
HASCO’s clamping fixture permits cost-
efficient clamping of mold plates that will
be processed. The precision positioning
holes in the corrosion-resistant clamping
plate of this device permit rapid and
secure variable clamping of differing mold
sizes, very high repeat accuracy in the
1/100 mm range, without having to fix the
zero point each time. Positioning/locking
washers with special expanding collet
system ensure that friction-locked and
keyed connection is achieved through
the system holes on mold plates.
DLC Coated Mold Components
With a comprehensive range of ejector
elements, 2-stage ejectors, guide locks,
latch locks, and the many different
combinations of ejector pins and ejector
sleeves. HASCO now offers DLC coating
on these parts as catalog standard items
for demolding in the field of injection
molding, die-casting, blow and compres-
sion molding. These components are
noted for their good slip properties, low
coefficients of friction and maximum
protection against corrosion and guar-
antee the highest possible quality.

WEBSITE PRODUCT CATEGORIES

For more than 90 years, HASCO has been • Mold Components
supporting its customer’s success with
agility, simplicity and performance. The
• Mold Bases
company & products will be presented • Mold Plates
in a new, clear appearance. HASCO is
• DLC Standard Components
the world’s leading supplier of modular
standard mold units, accessories and hot • Collapsible Cores
runner technology. The company’s hallmark • Unscrewing System
is based on state-of-the-art standardised
mold products. With over 700 employees • Hot Runner Components
worldwide, HASCO supplies the highest • Hot Runner Manifolds
quality products and services. Visit our
website for more information.
• Temperature Controls, Monitors, Sensors
hasco.com • Tool Steel/Mold Steels

48 MoldMaking Technology July 2014

HASCO – The Original for over 90 Years.
As the Original competence partner for the mold making and tooling industry,
HASCO is celebrating 90 years of proven precision and quality in 2014.
HASCO the leader in innovations with additional support and technical expertise
for the industry and schools around the world.
HASCO will celebrate the achievement of 90 years with many different global events.
For example HASCO America will have its 1st annual Customer Motorcycle Rally
with Open house at its US Headquarter in Fletcher, NC on September 12-14, 2014.
Sign up now at info.america@hasco.com !

HASCO Offers:
L An extensive range of standard mold units with

4
90

- 201
over 80,000 individual components
L Customized manufacturing

24
19
L Proven precision and quality
ASCO
L Quick and reliable delivery sH
year
L Individual hot runner solutions
L International service at over 35 locations
L Friendly service with Hasco employees, that stand 100% behind the product

Over 20.000 customers worldwide

Know-How,
put their trust in our
precision and quality of our products.
Join us and be a leader
in innovation.

www.hasco.com
HASCO America Inc. · 270 Rutledge Road, Unit B Fletcher, NC 28732 USA
Phone 877-427-2662 · Fax 828-684-7960 · quotes.america@hasco.com
Mold Components Pages 41 to 60
Pg. 5 to 9

PFA Inc. Phone: 262-250-4410

N118 W8251 Bunsen Dr. Fax: 262-250-4409
Germantown, WI 53022 US
pfa-inc.com

PRODUCTS/SERVICES
Modular Side-Action System—KOR-LOK®
The KOR-LOK® Side-Action System provides large pre-loads and ther-
mal compensation to core slides by the use of a dual-action, locking
intensifier at the end of a stroke. The threaded housing supports the
intensifier and the integral cylinder mechanism, and then transfers
the load between the mold base and the core slide through a set and
pull action.
To set the KOR-LOK, the rod is extended using pressure. As the
slide contacts the stop at the end of stroke, the locking segments
are forced into the rod groove by hydraulic pressure on the locking
slide. As the segments are squeezed, the rod and slide are compressed
forward against the stop under very high forces—removing flex and
thermal size variations. The final locking slide movement activates the
set sensor.
During the pull action, retracting pressure forces the locking slide
clear of the segments, allowing them to disengage as the rod and slide
are pulled. When fully retracted, the rear pull sensor is activated.
Additionally, the KOR-LOK can pull at any time, at any angle. It is
not a regular cylinder. It is free of plate movement and has controlled
pre-load stability, with on-the-fly adjustment. It can be adjusted in
critical areas without having to take the mold apart, which results in
less downtime. And, since the KOR-LOK is attached to the outside of
the mold, a smaller mold base can be used. This means the mold can
run in a smaller press—with less cycle time. Depending on the mold,
it can be as much as 15 to 30 percent.

WEBSITE PRODUCT CATEGORIES

PFA is a leader in locking style • Locking Core Pull Cylinders
cylinders for core pulls on
injection molds and die casting
• Mold Wiring
dies, quick mold change and • Quick Mold Change Systems
quick die change systems for
• Switches
injection molding, die casting,
metal stamping, and more.
pfa-inc.com

50 MoldMaking Technology July 2014

 ZERO FLASH
ON THE FIRST SHOT
Be proactive – Reduce mold size and complexity ile eliminating
tryout issues, mold t eaks, and expensive maintenance.

KOR-LOK
®

NEW SI
100 SER ZE!
SIDE-ACTION SYSTEMS
I ES

• 10x the Preload Power of • Easy mounting, preload adjustment

standard cylinders.
• Low pressure preload
activation – only 1,500 psi.
• Real Locking – Hydraulics
may be removed.
• 100% preload at ZERO psi
after lockup.
• Sensor verifies unit is
locked as expected.
and setup - No Shimming needed.
• Multiple Sensor &
Hydraulic Ports – Standard.
• Rear porting for
set and pull – Standard.
• Fast Delivery on ANY STROKE size.
• Easy Wiring – Dry Contact SPDT
Switches – Standard.

KOR-LOK® TRADITIONAL 3D Parametric CAD files now available online

SIDE-ACTION VS. SIDE-ACTION
SYSTEMS SYSTEMS Designed &
VISIT OUR WEBSITE FOR
Made in USA PFA'S ENTIRE FAMILY OF PRODUCTS
ES
! Mold OPEN
S!
Y Core Out
YE
N118 W18251 Bunsen Drive
S! Mold CLOSED
YE Core OUT CAN’T DO IT! Germantown, WI 53022
(262) 250-4410
S! S!
YE
Mold CLOSED
Fax (262) 250-4409
YE
Core IN

S! Against FULL
pfa-inc.com
Core PRE-LOADED

YE CAN’T DO IT! KOR-LOK®, Hydra-Latch™ and Hydra-Jaws™

Injection Pressure are trademarks of PFA, Inc.
©2013 PFA, Inc. All Rights Reserved.
Mold Components Pages 41 to 60
Pg. 5 to 9

Dalton Electric Heating Co., Inc. Phone: 978-356-9844

28 Hayward Street Fax: 978-356-9846
Ipswich, MA 01938
daltonelectric.com

PRODUCTS/SERVICES
Due to their unique split-sheath design,
The Cost of Process Heating Watt-Flex® heaters reduce the cost of
Watt-Flex vs. Conventional Cartridge Heaters process heating by as much as 40-50%!

Conventional Heaters Watt-Flex® heaters expand when energized

Watt-Flex Heaters
® for maximum bore contact and maximized
heat transfer; contract when de-energized
for warranted removability.

Improved heat transfer reduces power

consumption and significantly increases
heater life (often 50% longer than conven-
tional heaters).

Longer life reduces the cost of replacement

heaters and maintenance costs associated
with replacement.
Purchase Operating Replacement Routine Heater Total Cost
Price Costs Costs Maintenance Changeout of Process By eliminating bore seizure, Watt-Flex®
Costs Costs Heating
heaters minimize heater replacement time
and process downtime. They also prevent
damage to machines resulting from the
drillout of seized heaters.

WEBSITE PRODUCT CATEGORIES

Site describes advantages
of Watt-Flex® Split-Sheath
Cartridge Heaters; provides
specs, mounting configura-
tions, and lead modifications.
daltonelectric.com
• Hot Runner Systems and Supplies:
Hot Runner Components
• Mold Components:
Heating Equipment

52 MoldMaking Technology July 2014

 PREVENT
HEATING
®

Watt-Flex
Split-Sheath
Cartridge Heaters
Continuous heating coil ensures
uniform temperature profile and
eliminates cold sections
Split-sheath expands for maximum heat transfer
Higher warrantable watt densities and operating
temperatures than conventional heaters
Hot tip option

(978) 356-9844 www.daltonelectric.com

Mold Components

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ent

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COMPANY Advertisers are listed in bold type See Ad 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Alba Enterprises Inc., Rancho Cucamonga, CA, 909-941-0600 15
B A Die Mold, Inc., Aurora, IL, 630-978-4747 3 6
Better Molding Solutions, Ellington, CT, 860-454-8656
BMS Burns, Medina, OH, 800-345-7693 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16
Choice Mold Components Inc., Clinton Twp., MI, 586-783-5600 1 2 3 4 5 6 7 8 9 10 13 15 16
Collapsible Core, Inc., Channahon, IL, 630-408-1693 6
Craftsman Tool & Mold Co., Aurora, IL, 630-851-8700
Cross Tool & Manufacturing, Inc., Flagstaff, AZ, 928-779-4218 2
CUMSA USA, Troy, MI, 248-850-8385 58 5 6 7 8 15 16
Dalton Electric Heating Co., Inc., Ipswich, MA, 978-356-9844 53 14
DME Company, Madison Heights, MI, 248-398-6000 47 1 2 4 5 7 8 9 10 11 12 13 14 15 16
DMS, Oldcastle, ON, 519-737-6743 1 2 5 7 13 14 15 16
Edro Engineering and Specialty Steels, Inc., Walnut, CA, 909-594-5751 21
Ezell Precision Tool Co., Clearwater, FL, 727-573-3575 1 2 3 5 6 15 16
HASCO, Fletcher, NC, 828-650-2600 49 2 4 5 7 9 12 13 15 16
Hawk Mold & Die Supply Inc., Pipersville, PA 1 2 3 5 6 8 13 15
Hotset America Corp., Swainsboro, GA, 912-289-1844 2 8 9 11 12 13 14 15 16
IMS Company: Industrial Molding Supplies, Chagrin Falls, OH, 440-543-1615 1 4 8 14
Ipsco International, Attleboro, MA, 508-226-1776 2 5 9
Mac-Mold Base, Inc., Romeo, MI, 586-752-1956
Melt Design Inc., St. Charles, IL, 630-443-4000
Mold Base Industries Inc., Harrisburg, PA, 717-564-7960 56
Molders Choice Inc., Parma, OH, 216-458-1220 7 14 16
Nonnenmann Inc., Sterling Heights, MI, 586-977-8190 1 2 4 5 8 15 16
OMNI Mold Systems, Lisbon, CT, 888-666-4755 Cov 3, 42
PCS Company, Fraser, MI, 586-294-7780 Insert, 45 1 2 4 5 7 15 16
PFA Inc., Germantown, WI, 262-250-4410 51
Plastixs, LLC, Shrewsbury, MA, 508-842-1606 1 4 5 7 8 16
Precision Ground Inc., Lakemoor, IL, 815-578-2613 57 1 2 3 5 6 8
Precision Punch Corporation, Berlin, CT, 860-229-9902 5 8
Progressive Components, Wauconda, IL, 847-487-1000 Cov 2, 43 1 2 3 4 5 6 7 8 13 15 16
Roehr Tool Corporation, Hudson, MA, 978-562-4488 3 6
RUD-Chain, Inc., Hiawatha, IA, 319-294-0001
Self Lube, Coopersville, MI, 616-837-9721 2 5 8 13
Smith Enterprises, Wood Dale, IL, 630-595-0202 1 2 5 6 8
Superior Die Set Corporation, Oak Creek, WI, 414-764-4900 2 5 9
Technoject Machinery Corporation, Bolton, ON, 905-951-7144
Tempco Electric Heater Corp., Wood Dale, IL, 630-350-2252 14
TST North America Ltd., London, ON, 519-204-8334
Unitherm Insulation Systems, Lewisville, TX, 972-436-1401

For more supplier listings, go to moldmakingtechnology.com/suppliers

54 MoldMaking Technology July 2014

 Mold Components Pages 41 to 60
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17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 WEBSITE
19 20 21 22 30 31 32 33 34 35 36 37 41 albaent.com
badiemold.com
31 bettermolding.com
18 19 20 22 23 24 25 26 28 29 31 32 35 36 37 38 39 40 41 bmsburns.com
17 18 19 20 22 28 31 35 36 37 39 40 41 choicemold.com
collapsiblecore.com
23 craftsmanmold.com
18 20 24 30 35 37 crosstool.com
21 22 cumsa.com
daltonelectric.com
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 dme.net
18 20 22 23 24 28 31 32 35 36 37 39 40 41 dmscomponents.com
23 24 edro.com
17 18 19 20 22 23 28 31 33 34 35 36 37 39 41 ezellprecision.com
18 19 20 21 22 23 24 25 27 28 30 31 33 34 35 36 37 39 41 hasco.com/gb
18 19 20 22 23 24 27 31 32 35 36 hawkmold.com
18 19 21 22 28 31 35 36 37 38 39 41 hotset-worldwide.com
20 25 41 imscompany.com
18 20 35 37 41 ipscointernational.com
23 24 30 macmold.com
20 35 meltdesign.com
23 24 moldbase.com
25 30 molderschoice.com
18 20 35 36 37 39 nonnenmann-inc.com
19 22 23 24 28 31 omnimold.com
18 19 20 22 23 25 28 31 35 36 37 38 39 40 41 pcs-company.com
21 26 30 38 pfa-inc.com
22 26 30 38 plastixs.com
18 35 36 precisionground.net
18 36 ppunch.com
18 19 20 21 22 24 28 29 30 31 35 36 37 38 39 41 procomps.com
roehrtool.com
19 rudchain.com
18 19 22 28 31 35 41 selfube.com
36 smithpins.com
18 20 22 23 24 35 36 37 superiordieset.com
29 technoject.com
tempco.com
30 tst-northamerica.com
25 unitherm.com
Image courtesy of Vero Software.

moldmakingtechnology.com 55
Mold Components
Mold Monitoring Device Upgraded
AST Technology has introduced the second generation of its CVe Monitor,
which features a variety of upgrades that provide more options and increased
versatility.
The upgrades include a retrofitting capability that enables users to install
the monitor on an existing mold and input previous cycle counts; new alert
modes to notify users when preventive maintenance is due; pins on the back
of the device that record when it is removed from the tool for any reason;
mounting options at the parting line, below the parting line or on the mold’s
surface; increased flash drive storage; and upgraded OnDemand software.
AST Technology GmbH / 49 5221 7 630 695 / ast-tech.de
100% Quality
Assurance.
Quality you can trust!
Each MBI mold base is built to your exacting standards and
completed in the shortest possible lead time. MBI mold bases
are finish-machined so you simply install cavities, cores, and
auxiliary items, making your mold ready for testing.
Mold Base Industries, Inc.
7450 Derry Street, Harrisburg, PA 17111
Phone 800-241-6656 • FAX 717-564-2250
Internet: www.moldbase.com
E-mail: sales@moldbase.com
Custom Mold Bases • Self-Lubricating Components • Mold Plates
56 MoldMaking Technology July 2014
Pg. 5
Slide Retainers Available in More Sizes
Progressive Components has added four sizes to its SRT Series slide retain-
ers, which offer smooth, greaseless and reliable operation when holding side
actions, especially in cleanroom molding environments.
The slide retainers’ compact design allows installation in the mold base
or in wear plates. They feature newly engineered springs that offer tighter
tolerances and increased performance, refined force distribution that enables
a more impact-free operation, and color-coded springs for easy force-range
identification. Like units can be converted to other force ratings simply by
changing the springs.
The SRT product line now includes the new SRT-2/SRTM-01 with 2 lbs/1 kg
of slide holding force; the SRT-4/SRTM-02 with 4 lbs/2 kg of holding force; the
SRT-10/SRTM-04 with 10 lbs/4 kg of holding force; the new SRT-20/SRTM-09 with
20 lbs/9 kg of holding force; the SRT-30/SRTM-13 with 30 lbs/13 kg of holding
force; the new SRT-50/SRTM-22w with 50 lbs/22 kg of holding force; and the
SRT-80/SRTM-36 with 80 lbs/ 22 kg of slide holding force.
Progressive Components / 847-487-1000 / procomps.com
Injection Mold
Cooling System
Avoids Hot Spots
The CoolCross Z99 injec-
tion mold cooling system
from Hasco enables cool-
ing channels to cross each
other on the same plane
without a major manufac-
turing outlay. The system
features four-sided cavity
cooling and homogeneous temperature distribution that avoids hot spots. A
locking mechanism protects against rotation and the unintended closure of
the cooling channels.
Because the cooling circuits cross each other on the same plane, it is
possible to incorporate smaller plate thickness and inexpensive accessory
components in the mold design, the company says. The number of cooling
channels also can be reduced, since it is not necessary to have a cooling
channel in an additional plane. Reducing plate thickness also enables the use
of shorter nozzles, guidance elements and attachments, reducing the cost of
the components and the processing costs.
Hasco / 828-650-2600 / hasco.com
to 9 Mold Components Pages 41 to 60

Vertical Lifters Help Cut Machining, Tool Size

Cumsa offers a variety of vertical lifters designed to function with just one set
of ejector plates, offering the capability of using a standard component and the advantage of
designing one’s own insert. Benefits include reduced machining and tool size, and faster production
processes. According to Cumsa, the vertical lifters can release undercuts ranging to 26 mm with just
56 mm of ejection stroke.
Cumsa USA / 248-850-8385 / cumsa.com

Collapsible Cores Mold Very Small Parts

Sub-10 mm Dovetail (DT) collapsible cores from Roehr Tool Corp. are designed to mold very small
threaded or snap-fit parts without the use of hydraulics, while streamlining the overall size of the
mold and simplifying it for easy setup and molding operation.
Roehr Tool Corp. / 978-562-4488 / roehrtool.com

HSS Ejector Pins Available in Variety of Sizes

Regal Components’ Thru-Tuff M-2 HSS ejector pins are offered in fractional-inch sizes and oversize
diameters, in straight and shoulder styles, for flexibility in molding nylon and other parts with high-
glass-content resins. The pin heads are finished and chamfered for proper seating, through-hardened
to Rc 60-63, and annealed for increased toughness and ease of machining.
The pins are available in 6”, 8” and 10” lengths in both fractional (TT-type) diameters and standard
oversize (TTO-type) diameters of +0.0005”, +0.001”, +0.002” and 0.005”. Modifications such as heat
flats, vents and spherical radii are optional.
Regal Components Inc. / 800-760-5715 / regalcomps.com.

Expansion Boosts
Large Mold Base Production
DME has expanded mold base manufacturing
capabilities at its three North American manu-
facturing centers in Windsor, Ontario, Canada;
Youngwood, Pennsylvania; and Greenville,
Michigan, enabling the company to produce
large mold bases more quickly and efficient-
ly for moldmakers. The increased capacity
enables the Michigan manufacturing center to
produce mold base plates as long as 66”, as
wide as 54” and as thick as 13”. Larger equip-
ment work zones also accommodate tapping,
chamfering, spot-facing, counterboring, slot-
cutting, face milling, compound thread milling
and other processes on the mold bases.
DME Co. / 248-398-6000 / dme.net

moldmakingtechnology.com 57
Mold Components Pg. 5

Variety of Custom Mold Components Available

Precision Ground specializes in custom components for plastic injection molding, including cavity and
gate inserts; ejector, core and other pins; ejector sleeves; stripper bushings and rings; and complete
stack-up tooling. Using fully automated CNC machines and accurate digital readout systems, the com-
pany provides turning; milling; wire, sinker and small-hole EDM; ID, OD, centerless, surface and profile
grinding; gundrilling; honing; and production of round mold components.
Precision Ground Inc. / 815-578-2613 / precisionground.net

THE INVENTORS OF THE ORIGINAL

Undercuts Solutions

SPRUNG CORE INTRODUCES: Mold Bases and Components

THE MOST ADVANCED SPRUNG CORE EVER! Made from High-Quality Steel
Mold Base Industries manufactures custom
and standard mold bases, mold components and
Simple fixing system mold plate items from high-quality steel grades,
including standard #1 (ASTM A-36), #2 (AISI 4130),
#3 (modified P-20) and #4 (stainless steel holder
Flat prevents
block), as well as H-13 and aluminum.
twisting
Holder blocks made from the company’s pre-
hardened stainless are said to offer excellent
Extremely easy fine adjustment
Available in 3 different lengths 175, machinability, uniform hardness and resistance
with the provided stopper
250 and 325mm. to corrosion caused by engineering resins and
humid working or storage conditions. Increased
heat transfer from corrosion-free water channels
20 years working with spring steel also lowers production costs.
gives us guaranteed knowledge Mold Base Industries Inc. /
717-564-7960 / moldbase.com
Manufactured undercut Zero point /
(single clip) Mechanical stopper

Adjusted to fit a H7 housing

Radius already provided

on the sprung core head

More than 500.000 units Adjustable-Position Pins

Ease Cavity Realignment
sold worldwide!!! DMS’ adjustable-position leader pins are
Cutting jig to ensure
designed so that one cavity plate position
precise PX length
can be easily moved in relation to the other
Contact us, and we will find the best solution for your mold! cavity plate position, reducing the time and
cost associated with conventional cavity
CUMSA USA, LLC WEB: www.cumsa.com
950 Stephenson Hwy (Suite 106) MAIL: info@cumsausa.com realignment procedures.
MI-48083 - Troy TEL.: +1 248 850 8385 DMS / 519-737-6743 /
United States FAX: +1 248 850 8385 dmscomponents.com

58 MoldMaking Technology July 2014

 PHOTOS: THINKSTOCK.COM
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Mold Components Mold Components Pages 41 to 60 Pg. 5

Access video
VIDEO at end of article.

The Value of Insourcing

and Standardizing
Component Work

By Paul Coleman
Aalbers Tool and Mold has experienced numerous benefits
from the standardization and in-house manufacturing of its
mold components, including:
Fewer opportunities for error. “Our designers are aware
of the sizes in stock, and they use those sizes whenever pos-
sible,” notes Engineering Manager Don Stockwell. “Each plate
is part of our CAD library in TopSolid. The models contain

Image courtesy of Aalbers Tool and Mold.

everything: wear plates, pockets, screws and screw holes—all
finished. In addition, we keep all manufacturing information
on file for each size. This reuse of information saves us time
with each design and also reduces opportunity for error.”
Decreased manufacturing time. “In the past, a custom com-
ponent would take a fair amount of time to produce,” company
President Toni Hansen points out. “We now manufacture them
in batches using an automated process. It takes less time and
has reduced the chance of errors. One custom component could Each plate design is part of Aalbers’ CAD library in TopSolid. The models
take 30 minutes to produce, but now we can produce 10 of contain everything: wear plates, pockets, screws and screw holes—all fnished.
In addition, the company stores all manufacturing information for each plate
them in the same amount of time—a 90-perent savings in labor.” size, saving time with each design and reducing opportunities for error.
Reduced lead times. As a result, lead times at Aalbers have
been significantly impacted. “We can produce molds faster
because no one is waiting for a custom part to be manufac- improving component design. Team leaders from design, manu-
tured. We always have our own components in stock,” Hansen facturing and sales meet to ensure everyone is looking at improve-
says. Aalbers still purchases a few standard components from ments from all aspects.
other suppliers, but if there is ever a problem with lead time The goal is simple, Hansen says. “It has to improve time, quality
on these orders, the component division can quickly manufac- and help lower costs. We still purchase some components from
ture the part to order. suppliers, but what started with a few components has now
Improved customer service. Standardization has truly grown to a large library of our own standard components.”
benefited Aalbers customers, according to Doug Thompson
of company’s technical sales department. “If a part gets dam-
CONTRIBUTOR
aged or worn, we can quickly take one off the shelf and send it
Paul Coleman is president of Creation Design Inc.
along to the customer. No more waiting for a custom part to
be manufactured.” VIDEO:
Hidden cost savings. Parametric CAD systems enable Precision Mold Specialists
designers to design parts to any size they desire, but this flex- short.moldmakingtechnology.com/aalbers
ibility can also be a big problem, according to Hansen. In addi-
tion to the increased potential for actual engineering errors,
allowing a designer to pick any size he wants can have drastic FOR MORE INFORMATION:
cost implications that may not be caught until it’s too late. Aalbers Tool and Mold / 519-737-1369 / aalberstool.com
Continuous improvement. Standardization also has helped Missler Software Inc. (TopSolid) / 630-889-8055 / topsolid.com
foster a culture of continuous improvement at Aalbers. The Creation Design Inc. / 226-346-5077 / creationdesigninc.com
company now holds monthly meetings to discuss ideas for

60 MoldMaking Technology July 2014

 Pages 61 to 84

Cutting Tools
Pages xxx to xxx

Image courtesy of Sandvik.

moldmakingtechnology.com 61
 25th International Conference and Exhibits

June 16–18, 2015

rosemont, il Molding 2015 is a unique event
focusing on innovations in molding
consumer and industrial products.

Call for Papers! At Molding 2015, industry leaders

discuss the latest developments in
various molding processes, hardware
AbstrAct DeADline
and controls with special emphasis
on adding business value.
september 19th, 2014

The organizing committee for the

Molding 2015 conference is accepting
abstracts on the following topics:
• Emerging Technologies
• Sustainable Manufacturing
• Adding Value: Automations/
Assembly/Packaging
• LSR Molding
• Medical Molding
• Molding for Electronics

Co-located with:

Presented by:

Photo Sources: (clockwise)

Vero Software; iStock; KraussMaffei

How to submit your abstracts:

Online: ptonline/conferences/molding2015
submit your abstract today! Email: agolovoy@gmail.com
Cutting Tools Pages 61 to 84

Sandvik Coromant Toll-free: 1-800-SANDVIK (1-800-726-3845)

1702 Nevins Road Phone: 201-794-5000
P.O. Box 428 Fax: 201-794-5165
Email: us.coromant@sandvik.com
Fair Lawn, NJ 07410-0428
sandvik.coromant.com/us
facebook.com/SandvikCoromantUS
twitter.com/sandvikcoro_US

PRODUCTS/SERVICES

Disc Cutting Concepts
The CoroMill® 172 and 171 disc cutting
concepts adapted for gears, splines and
racks enable single setup gear profile
manufacturing on most types of CNC
machines. CoroMill® 172 and 171 disc
cutters offer an easy-to-program, versa-
tile and time saving solution for milling
of high-quality gear profiles. Thanks
to indexable carbide insert technology
components can be machined inflexible,
non-dedicated machines, such as multi-
task machines and machining centers,
as well as in hobbing machines.
Solid Carbide Drills For
Stainless Steel
CoroDrill® 860 is a solid carbide drill
designed for a fast and problem-free
drilling. It maximizes productivity through
high metal cutting efficiency and machine
utilization. With excellent chip evacuation
in long and short chipping materials,
CoroDrill 860 provides green light
machining at high penetration rates. The
CoroDrill 860 product offer consists of
three drill geometries—optimized for
steel, stainless steel, and aluminum. The
drill comes in lengths 3-8×D as standard.
High Feed Milling Concept
CoroMill 419 is a new five-edge high-
feed milling concept for roughing to
semi-finishing, offering excellent
performance in all material groups and
with great possibilities for optimization.
The new milling cutter is suitable for
most applications and industry segments
requiring high feed face and profile
milling.
It is well suited to machining of com-
ponents requiring long overhangs and
even perfect for lower-power machines
and weak fixtures.

WEBSITE PRODUCT CATEGORIES

Products and solutions, • Cutting Tools
features and benefits;
• End Mills
online catalogs for
data and CAD drawings; • Inserts
worldwide support, • Lathe Tooling and Accessories
service and training.
• Toolholders

sandvik.coromant.com/us

moldmakingtechnology.com 63
Cutting Tools Pages 61 to 84

Iscar Metals, Inc. Phone: 817-258-3200

300 Westway Place Toll-Free: 877-294-7227
Fax: 817-258-3221
Arlington, TX 76018-1021
Email: info@iscarmetals.com

iscarmetals.com

PRODUCTS/SERVICES
Machining Intelligently ISCAR’s new HIGHQLINE
ISCAR continues to expand its existing array of products which is the company’s answer
established many benchmarks in the global metalworking to global market requests.
industry. The new ISCAR IQ campaign introduces several new ISCAR has always been at
innovative tool families the heart of manufacturing
The tool families under the new HIGHQLINE campaign and shall continue to be
help to increase profitability by employing leading-edge engi- for many decades to come.
neering solutions. These new ISCAR tools will enable manufac- The new tools are a part
turers to continue to improve their efficiency in metalworking of ISCAR’s commitment
by using modern machining strategies under ISCAR’s new to the ongoing success of
campaign motto “Machining Intelligently.” The new tools focus its customers. As manu-
on increased productivity with smart insert locking mecha- facturers struggle to meet
nisms, which create a more stable machining process. ISCAR increasing demands, ISCAR
has responded to the new market demands resulting from the will use the HIGHQLINE campaign to encourage technical
trend toward high speed machining and mill-turn CNC, with education in automation and advanced technologies in all sec-
upgrades in both tool and insert geometries, leading to less tors of the metalworking industry by
machine downtime and less labor. promoting the motto “Machining Intelligently”.
In today’s economy with tight resources, lean operations and Some of ISCAR’s best ideas have resulted from its R&D engi-
challenging demands, manufacturers need more support from neers working with their field engineers, who are out in the
their supply partners. ISCAR strives to work closely with custom- real world listening to the needs of their customers. Creativity
ers, not only to develop new technologies that meet emerging in metalworking is a way of life at ISCAR.
needs, but also to maximize the value of investments in modern To enhance customer support, ISCAR continues to develop
machinery by increasing equipment utilization and optimizing its unique IBAQUS, a unique package of 5 Technical Apps
performance. ISCAR’s new HIGHQLINE tools are well-suited for found at iscarmetals.com. Take a look at the MATRIX, Iscar’s
the new generation of machining centers, enabling high feeds inventory management system, when visiting the
and speeds for highly productive machining operations. website to download the IBAQUS Apps.

WEBSITE PRODUCT CATEGORIES

Iscar is a dynamic full line supplier • Cutting Tools
of carbide metal cutting tools which
• End Mills
cover a broad range of applications and
industries. Browse Iscar’s site to find • Inserts
the newest innovations in metal remov-
• Lathe Tooling and Accessories
al. Contact Iscar for more information.
www.iscarmetals.com • Reamers
• Toolholders
• Tool Selection Software (ITA)

64 MoldMaking Technology July 2014

 ImiVtation
No Time Don't
forSettleLook
for Less
Alikes!
Use ISCAR's Innovative Products

15,000
Indexable Solid Carbide Endmill Options

Machining Intelligently
ISCAR HIGH Q LINES www.iscarmetals.com
Cutting Tools Pages 61 to 84

Walter USA, LLC Phone: 800-945-5554

N22 W23855 Fax: 262-347-2500
Ridgeview Parkway W. Email: service.us@walter-tools.com
Waukesha, WI 53188
walter-tools.com/us

PRODUCTS/SERVICES
Walter Titex X•treme line of
standard deep-hole drills can now
reach a drilling depth of 50 x Diameter.
Walter has expanded its range of tough, reliable and long-life
standard solid carbide deep-hole drills with the introduction of
the Walter Titex X•treme D40 and the X•treme D50. Previously,
the standard range of XD drills reached up to 30xD, with longer tools up to
70xD available as special versions. Now, however, with the introduction of the
X•treme D40 and D50 with their 40xD and 50xD drilling depths respectively,
that standard range has been significantly increased. Walter’s XD technology
(XD stands for extremely deep) enables holes to be drilled in one operation
without pecking, in steel, cast iron or non-ferrous metals.
Built with the latest production technology, the new X•treme D40 and D50
drills also have an advanced TiALN-tip coating for a long tool life. Additional
features include internal coolant channels for optimum heat dissipation and reli-
able chip evacuation. The latter is also supported by polished flutes. Four margins
keep the drill exactly on its intended course. These features ensure a high level
of process reliability, even with angled hole exits or cross holes. A high-pressure
coolant system is not required – in order to plunge without “coming up for air” a The new Walter Titex D40
standard system with a coolant pressure of 580 psi (40 bar), such as is integrated X•treme expands the standard
in all machining centers, is sufficient. Typical applications for these diameters are range of solid carbide deep-hole
drills for extreme drilling depths.
general metalworking, and the hydraulics and automotive industries. Additional
diameters, including intermediate sizes, are available as special versions.

WEBSITE PRODUCT CATEGORIES

• Drills
• End Mills
• Grooving Tools
• Inserts, indexable (carbide, etc.) & Tool inserts
• Milling Cutters
• Taps
• Thread Milling Cutters
walter-tools.com/us
• Threading Tools
• Tool holders & Adaptors

66 MoldMaking Technology July 2014

 Fully integrated performance

The high-performance drill for increased Visit us at IMTS

productivity and process reliability.
Walter Titex is attracting buyers from across Booth W-1700
different industries with more process reliability
accompanied by an increase in productivity. You
too can benefit from innovative point geometries
and coatings, and from assured chip evacuation
and ground-breaking internal cooling.

Find out more at: www.walter-tools.com X·treme M

XD 70

Walter Titex X·treme

WALTER NORTH AMERICA

Walter USA, LLC
N22W23855 RidgeView Pkwy W
Waukesha, WI 53188, USA
800-945-5554
service.us@walter-tools.com
Walter Canada
N22W23855 RidgeView Pkwy W
Waukesha, WI 53188, USA
800-945-5554
service.ca@walter-tools.com
Walter Tools S.A. de C.V.
Carr. Estatal KM 2.22 #431, Módulo 3, Interior 19 y 20
El Colorado Galindo, Municipio El Marqués,
Querétaro, C.P. 76246, México
+52 442-478-3500
service.mx@walter-tools.com

www.walter-tools.com/us www.youtube.com/waltertools www.facebook.com/waltertools

Cutting Tools
PRODUCTS/SERVICES
Hi-QuadF™ High-Feed Quad
Ingersoll’s Hi-QuadF™ high-feed milling
line offers both a 13mm and 19mm IC
quad-style insert. The insert provides
4 cutting edges with 8 different edge
geometries. Premium insert grades
and optimal edge preparations ensure
long tool life across the widest range of
materials.
The positive axial insert orientation
creates the high-shear, free-cutting
action. Chip thinning is leveraged to a
factor of 5X when calculating feed rates.
A robust insert screw design ensures
insert seating stability.
WEBSITE
Ingersoll’s web page offers an array of product information via pdf
and electronic catalogs, promotions, updates and a wide range of
product application videos showcasing our 100 years of metalcutting
innovation.
ingersoll-imc.com
68 MoldMaking Technology July 2014
Ingersoll Cutting Tools
845 S Lyford Rd.
Rockford, IL 61108
T-Micro™ Small ID Boring
Ingersoll’s T-Micro boring system
is designed for small internal diam-
eters. The 2-piece design consists of a
sleeve and replaceable carbide inserts.
Applications include grooving, profiling,
chamfering, deep face grooving, thread-
ing, and back turning starting at .024”
(.6mm). The inserts feature coolant thru.
A locating pin ensures repeatability,
allowing operators to replace inserts
right in the machine. The sleeve features
angular clamping to avoid interference
when replacing inserts on Swiss-type
and other multi-spindle lathes.
PRODUCT CATEGORIES
• Hot Runners
• Cutting Tools
• Machining
Pages 61 to 84
Toll-free: 866-690-1859
Phone: 815-387-6600
Fax: 815-387-6968
Email: info@ingersoll-imc.com
ingersoll-imc.com
Hi-FeedMidi™ High-Feed Mills
The new Hi-FeedMidi milling family offers
all the features of Ingersoll’s successful
Hi-FeedMini™, but with a .060” depth of
cut.
Strong, positive rake face angles, four
insert indexes, rigid clamping and high
tensile screws provide efficient, worry-
free, cost-effective machining.
The Hi-FeedMidi family is available
in high-density end mill, modular head
and face mill styles with through coolant.
These high-feed cutters are well-suited to
Die/Mold and Aerospace, as well as gen-
eral purpose machining.
Cutting Tools Pages 61 to 84

Sumitomo Electric Phone: 847-635-0044

Carbide, Inc. Toll-Free: 800-950-5202
1001 Business Center Dr. Fax: 847-635-7866
Mt. Prospect, IL 60056
sumicarbide.com

PRODUCTS/SERVICES

MSX High Feed Endmill RSX SEC-Wave Radius

High Feed Rates—up to 0.055 IPT Mill Cutter Series
Higher clamping rigidity due to double RSX SEC-Wave Radius Mill Cutter Series
clamping system Available in 0.750" - is designed for a wide variety of applica-
1.500" bodies with air holes for improved tions, including face milling, ramping,
chip evacuation Capable of both ramp- slotting, 3-D interpolation and helical
ing and heical boring applications. boring.
Solid Carbide GS Drill Series Featuring a highly durable body, which
The solid carbide GS Drill Series—the consists of special alloyed steel and is
new “Global Standard” in solid carbide protected by a hard surface treatment.
drilling. With an advanced carbide sub- To meet strict application requirements,
strate and highly wear resistant DEX Sumitomo provides a range of insert
coating, the GS Drill Series allows for grades and coatings for the RSX Series.
increased feed rates and running speed.

WEBSITE PRODUCT CATEGORIES

For 35 years, we've made it our • CBN
mission to design and produce
exceptionally innovative and • Cutting Tools
advanced cutting tool solutions. • Drills
Our aggressive R&D and design
ingenuity give you more choices
• End Mills
in turning systems, drilling sys- • Hard Milling
tems, milling systems and inserts,
• Inserts
including PCBN and PCD coated
versions. Every Sumitomo solution • Lathe Tooling and Accessories
is painstakingly developed to meet • Toolholders
your need for higher productivity
and precision.
sumicarbide.com

70 MoldMaking Technology July 2014

 O FF
5 0% BO DY
T E R
C UT
or
FRE E ITH
ODY W
ER B E OF
C UT T
U R C HAS POCKET
A P SERTS/
10 IN

PWS MSX RSX

Tangential Shoulder Milling Cutter High Feed Milling Cutter Milling Cutter for Complex Parts

Highly reliable shoulder mill tangentially High Feed Milling Cutter boasts up to Wide application range includes face
mounted for never-before-possible cut- 0.055 IPT feed rates. milling, ramping, slotting, 3-D interpo-
ting edge strength. lation and helical boring.

Please visit www.sumicarbide.com for more

information regarding Sumitomo Promotions.

1001 Business Center Drive • Mount Prospect, Illinois 60056

Telephone (800) 950-5202 • Fax (847) 635-9335
www.sumicarbide.com Booth #W-2422
Cutting Tools Pages 61 to 84

Scientific Cutting Tools, Inc. Toll-free: 800-383-2244

110 W. Easy Street Phone: 805-584-9495
Simi Valley, CA 93065 Fax: 805-584-9629

sct-usa.com

PRODUCTS/SERVICES

Port Tools SCT Advantage Acme and Stub Acme

SCT is a leading manufacturer of car-
bide tipped porting tools and tapered
pipe reamers. Popular industry standard
port tools that conform to military
and aerospace specifications include
AS5202, J1926, J514, ISO 6149, AS1300
and MS33514, as well as cavity tools for
Hydraforce and Sun Hydraulics and pipe
reamers for BSPP and NPT/NPTF forms.
Special port and cavity tools quoted
upon request.
Scientific Cutting Tools, in keeping with
its promise to remain on “the cutting
edge,” introduces a revolutionary new
design for indexable boring bar technol-
ogy with the SCT Advantage indexable
cutting tool system. The innovative
design of the tool holder puts extra
material where needed for strength
and chip control coupled with a preci-
sion ground insert with superior finish
and a low profile designed screw, your
small diameter boring operations were
never easier. All new specially designed
chip control inserts with ground in chip
breakers make internal boring opera-
tions in difficult to machine materials
easier than ever. Get the SCT Advantage.
Do you have a part with an Acme thread
that needs to be run on a machining
center? SCT offers a complete line of
solid carbide Acme & Stub Acme single
profile thread milling cutters for inter-
nal threads. In thread sizes starting at
1/4-16 and going up to and including a
1.00" - 5 in uncoated and TiALN-coated
micrograin carbide. Long and standard
length versions available from stock.
These tools will give you a number of
distinct advantages over tapping when
cutting deep Acme threads including
reduced horsepower requirements and
better surface finish. Free programming
assistance available.

WEBSITE PRODUCT CATEGORIES

Scientific Cutting Tools offers • Boring Tools
an array of standard and cus-
• Chamfering Tools
tom cutting tools made from
the finest sub-micron carbide • Cutting Tools
and high speed steel. Browse • Diamond Tools
SCT’s web site to find the new-
est innovations in indexable
• Inserts
tooling, Acme and Stub Acme • Lathe Tooling and Accessories
solid carbide single and profile • Reamers
thread mills. The SCT web site
includes a complete catalog of • Serration Tooling
products along with a thread • Threading Tools
mill feed and speed chart. • Toolholders
sct-usa.com

72 MoldMaking Technology July 2014

Cutting Tools Pages 61 to 84

Drill Master - Eldorado Tool Inc. Phone: 203-878-1711

336 Boston Post Rd. Toll-Free: 800-658-8855
Fax: 203-878-6156
Milford, CT 06460
dmetool.com/mmt

PRODUCTS/SERVICES
Drill Masters-Eldorado Tool is one of the largest suppliers and manufacturers
of deep hole gun drilling tools, fixtures, and accessories in the world. Our com-
bined experience and resources offer the widest selection of in-stock deep hole
gundrills and the greatest range of products, services, and experience proudly
made and based in the United States. Add our rapid delivery and expanded cus-
tomer service facilities, and it’s apparent why we’re the leader in gundrilling for
parts, service, and innovative assistance.
We stock over 800 sizes and lengths in number, letter, metric, and fraction
sizes which are all available for same day delivery. In order to respond to the
immediate needs of the mold making industry, our in-stock lengths range from
48" thru 72". Our 24 hour delivery of stock gundrills provide the flexibility for
job shops and mold shops to respond to their customer's hole needs, therefore
providing faster service and a more competitive edge. Our expedited delivery
program enables customers to purchase special diameters and lengths outside of
the realm of stock standards.
In 1948, Eldorado Tool was founded to manufacture cutting tools and man-
drels for deep hole drilling. The company’s reputation and range of products
grew through the 1950s, and in 1961, Eldorado developed a full line of standard
gundrilling machines. In the 1970s they became the first to introduce a complete
line of deep hole drilling tools, machines, fixtures and accessories for the metal-
working industry.
By the year 2000, Drill Masters and Eldorado became two of the leading
designers and manufacturers of deep hole drilling tools, machines, fixtures, and
accessories. Combining of these two leaders in 2002 has made Drill Masters-
Eldorado Tool one of the largest suppliers and manufacturers of deep hole drill-
ing tools, fixtures, and accessories in the world.

WEBSITE PRODUCT CATEGORIES

We stock over 800 sizes and lengths • Cutting Tools
in number, letter, metric, and fraction
• Reamers
sizes which are all available for same
day delivery. In order to respond to
the immediate needs of the mold
making industry, our in-stock lengths
range from 48” thru 72”. Our 24 hour
delivery of stock gundrills provide the
flexibility for job shops and mold shops
to respond to their customer’s hole
needs, therefore providing faster
service and a more competitive edge.
dmetool.com/mmt

74 MoldMaking Technology July 2014

Cutting Tools Pages 61 to 84

Micro 100 Tool Corporation Phone: 800-421-8065

1410 East Pine Avenue Fax: 208-888-2106
Meridian, ID 83642

micro100.com

PRODUCTS/SERVICES

MICRO 100 Quick Change MICRO 100 MEF

The MICRO 100 Quick Change unique “3 point” locking system
ensures tool to tool repeatability of plus or minus .0005”. Quick
Change allows for tool changes in 30 seconds or less. Solid carbide
quick change tools are offered in 19 popular tool styles ranging
from boring and grooving tools to threading tools. New styles of
holders now offered for use in Star machines. Tools and holders
are offered in both inch standard and metric dimensions.
The NEW MICRO 100 MEF family of tools are all 2 fluted
miniature end mills available in both inch and metric sizes
starting as small as .0100” in cutter diameter. These high
precision miniature mills are ideal for finishing and semi-
finishing cuts in hardened materials 45 to 68 Rc materials.
Their Extra Fine carbide substrate also makes them well-suited
for mold making. They are also available in nACRo coating.

WEBSITE PRODUCT CATEGORIES

• Boring Tools
• Cutting Tools
• End Mills
• Engraving Tools
• Inserts
• Lathe Tooling & Accessories
• Proflers
• Toolholders

micro100.com

76 MoldMaking Technology July 2014

 QUALITY TOOLS MAKE A DIFFERENCE!

MACHINE
HARDENED
MATERIALS
HARD MILLING MINIATURE
SQUARE AND BALL NOSE
46-68 Rc!

END MILLS
Miniature Variable Helix End Mills Engineered for Milling Applications in
Hardened Steels, Aluminum Alloys, Exotic Alloys, Graphite and Composite Materials.
1.5 to 12 Times Reach Lengths in both Inch and Metric sizes.
CUTTING
DIAMETERS
Coated and Uncoated End Mills Available.
STARTING AT
0.010"
Manufactured with the Exclusive MICRO 100 Treating Process.

i cr o QuIk
QUICK CHANGE TOOLING

HIGH QUALITY...HIGH PRECISION

QUICK-CHANGE TOOLING SYSTEM

Uniquely Engineered "3 Point" Locking/Locating

Features Maximum Tool Rigidity and
Centerline Repeatability within +.0005"
from Tool to Tool!
Uniquely Reduce Machine Setup, Downtime,
Tooling Costs, and Tooling Inventories
all while Boosting Productivity! CHANGE TOOLS
IN...
0:30 SECONDS
Manufactured with the OR LESS!

Exclusive MICRO 100 Treating Process.

CONTACT YOUR LOCAL AUTHORIZED MICRO 100 DISTRIBUTOR TODAY...OR CONTACT US FOR MORE DETAILS

WILL NOT CHIP OR BREAK UNDER NORMAL MACHINING CONDITIONS

800-421-8065 www.micro100.com 208-888-7310

Cutting Tools

els
ids

Whe
ols

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nts

ding
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Cutt

Cutt

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End
COMPANY Advertisers are listed in bold type See Ad 1 2 3 4 5 6
BIG Kaiser Precision Tooling Inc., Hoffman Estates, IL, 847-228-7660 3 4
Cole Carbide Industries, Inc., Orion Township, MI, 586-757-8700 81 3 4 6
CVD Diamond Corporation, London, ON, 519-457-9903 3 4
Dapra Corporation, Bloomfeld, CT, 860-242-8539 3 4 6
Darex, Ashland, OR, 541-488-2224 3 4
Data Flute, Pittsfeld, MA, 413-499-3895 3 4
Drill Master - Eldorado Tool Inc., Milford, CT, 203-878-1711 75 3
Emuge Corp., West Boylston, MA, 508-595-3600 2 3 4
Greenleaf Corporation, Saegertown, PA, 814-763-2915 3 4 6
Guhring Inc., Brookfeld, WI, 262-784-6730 3 4
Haimer USA, Villa Park, IL, 630-833-1500 3 4 6
Hirschmann Engineering USA, Inc., Schaumburg, IL, 847-468-9700
Hitachi Metals America, LTD., Novi, MI, 248-465-6400 3 4
Horn USA Inc., Franklin, TN, 615-771-4100 3 4 6
Ingersoll Cutting Tools, Rockford, IL, 815-387-6600 69 3 4 6
Iscar Metals, Inc., Arlington, TX, 817-258-3200 65 3 4
ITW Fluids North America, Glenview, IL, 847-657-5278 1 2
Kennametal Inc., Latrobe, PA, 800-446-7738 2 3 4 5
LMT USA, Inc., Waukegan, IL, 847-693-3270 3 4
Lyndex - Nikken, Inc., Mundelein, IL, 847-367-4800
Melin Tool Company, Cleveland, OH, 216-362-4200 3 4
Micro 100 Tool Corp., Meridian, ID, 208-888-7310 77 3 4
Millstar, Orion Twp., MI, 586-573-9450 81 3 4 6
Niagara Cutter, Reynoldsville, PA, 814-653-8211 3 4
NSK America Corp., Hoffman Estates, IL, 847-843-7664
OSG Tap & Die, Inc., Glendale Heights, IL, 630-790-1400 3 4
REGO-FIX Tool Corp., Indianapolis, IN, 317-870-5959
RobbJack Corp./Crystallume, Lincoln, CA, 916-645-6045 3 4
RoundTool Laboratories, Huntington Beach, CA, 714-898-9224 3 4 6
Sandvik Coromant Co., Fair Lawn, NJ, 201-794-5000 Cov 4, 63 3 4
SCHUNK Inc., Morrisville, NC, 919-572-2705 3
Scientifc Cutting Tools, Simi Valley, CA, 805-584-9495 73 3
Seco Tools, LLC, Troy, MI, 248-528-5200 3 4 6
Single Source Technologies, Auburn Hills, MI, 248-232-6232 99 1 2 3 4
Sumitomo Electric Carbide, Inc., Mt. Prospect, IL, 847-635-0044 71 3 4 6
Tool Alliance, Huntington Beach, CA, 714-898-9224 83 3
Tool Fabrication Corporation, Milwaukee, WI, 414-453-5030 3 4
Tool-Flo Manufacturing Inc., Houston, TX, 713-941-1080 3 4
U.S. Union Tool, Inc., Anaheim, CA, 714-521-6242 3 4 6
Walter USA, LLC, Waukesha, WI, 262-347-2400 67 1 3 4

For more supplier listings, go to moldmakingtechnology.com/suppliers

78 MoldMaking Technology July 2014

 Cutting Tools Pages 61 to 84

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es

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High

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Inse

Tool

Tool

Tool
Rea
7 8 9 10 11 12 13 14 15 WEBSITE
9 10 13 15 bigkaiser.com
7 9 10 11 12 15 colecarbide.com
cvddiamond.com
7 9 dapra.com
darex.com
datafute.com
12 dmetool.com
9 10 12 15 emuge.com
7 9 10 15 greenleafcorporation.com
9 12 15 guhring.com
7 13 14 15 haimer-usa.com
14 hirschmannusa.com
9 hitachitoolusa.com
7 9 10 11 12 15 hornusa.com
7 9 10 12 13 15 ingersoll-imc.com
9 10 12 15 iscarmetals.com
itwfuidsna.com
9 10 11 12 15 kennametal.com
9 10 lmtusa.com
12 15 lyndexnikken.com
12 melintool.com
9 10 11 12 15 micro100.com
7 9 15 millstar.com
niagaracutter.com
7 8 nskamericacorp.com
9 12 15 osgtool.com
15 rego-fx.com
9 robbjack.com
7 roundtool.com
9 10 15 sandvik.coromant.com/us
10 14 15 us.schunk.com
9 10 11 12 15 sct-usa.com
7 9 10 12 13 15 secotools.com/us
8 9 14 15 singlesourcetech.com
9 10 15 sumicarbide.com
toolalliance.com
9 10 12 15 toolfab.com
9 11 15 toolfo.com
7 usuniontool.com
9 10 11 12 15 walter-tools.com/us
Image courtesy of Seco Tools.

moldmakingtechnology.com 79
Cutting Tools

Exchangeable-Tip Drill Available for

Stainless Steel
The CoroDrill 870 exchangeable-tip drill from Sandvik
Coromant is designed to reduce costs per hole and
save time when drilling in stainless steel, as
well as cast iron. The drill can be tailored to
optimize applications through diameter
range, steps and length possibilities.
According to the company, holes
can be made more efficiently and
closer to the specifications required,
leaving them better-suited to subsequent operations. A secure interface
between drill body and tip ensures reliability and precision, while a tip-change
procedure designed to be quick and easy maximizes active machining time.
New cutting edge geometries and grades are said to provide a safe cutting process, enabling High-Feed Milling Insert
increased penetration rates, while maintaining chip control and increasing tool life. Grade GC2234 Offers 8 Cutting Edges
includes a fine-grained, high-chromium substrate and a PVD coating with optimized composition for The SNKX high-feed square milling insert from
ISO M drilling (stainless). The thin AlTiN PVD coating includes enhanced adhesion steps designed for Techniks’ Nexus Cutting Tools line features eight
longer tool life and increased chipping resistance. corners with helical geometry to deliver more
The CoroDrill 870 is available in diameters ranging from 10 to 26.65 mm (0.394” to 1.049”) and cutting edges per insert for increased productiv-
lengths of as much as 8x drill diameter. Each drill body has a unique interface size with matching tips ity. The insert is manufactured from sub-micro-
to achieve hole tolerances of H9–H10. grain carbide and with advanced PVD coating
Sandvik Coromant / 800-726-3845 / sandvik.coromant.com technology that is said to be thicker than most
PVD coatings. This enables machining of multiple
materials and improves tool life.
Spline Connection Adds Durability to T-Slot Cutters Offering high material removal rates, the cut-
Iscar’s SD-SP15 narrow slotting and groove milling cutters consist of interchangeable solid carbide ters are suited for applications such as face
T-slot milling heads and cylindrical steel shanks assembled by means of a spline connection. The cutter milling, copy milling, plunge milling and roughing
heads feature an SP15 internal spline mounted on a matching external spline on the shank secured by operations on pockets and 3D surfaces. They are
a central screw. The SP15 spline connection (“15” indicates the connection size), used to transmit the available in standard Weldon shank end mills and
torque, ensures a durable assembly that can withstand high cutting forces during slot milling as well face mills, or in Power-Loc and shrink-mill designs
as bending forces caused by long reach overhang, the company says. for zero runout.
An adapter also is available for all T12 standard Multi-Master shanks, featuring the SP spline connec- Techniks Inc. / 317-803-8000 /
tion on one side and a T12 Multi- techniksusa.com
Master threaded connection on
the other side.
The SD-SP15 cutters feature
1.25”-diameter milling heads Ballnose End Mills Produce
with eight teeth ranging in High-Quality Finishes
width from 0.125” to 0.250” for Data Flute’s Die Mold series of solid carbide
depths of cut ranging to 0.315”. ballnose end mills for hard-milling, mold appli-
The heads’ general-duty cutting cations includes tapered, necked and straight
geometry is said to be well-suit- shank models.
ed for efficient slot milling on a According to the company, these material- and
variety of workpiece materials. application-specific tools are designed to allow
The heads are made from IC908 machinists to use the newest, most produc-
grade and are based on the tive high-speed machining techniques to achieve
cutting geometry of the MM-TS superior finishes that require little or no hand-
Multi-Master heads. work, while also extending tool life, in a range of
Iscar Metals Inc. / ferrous and non-ferrous metals.
877-294-7227 / Data Flute / 800-447-1476 /
iscarmetals.com dataflute.com

80 MoldMaking Technology July 2014

 Cutting Tools Pages 61 to 84

Shoulder Mill Handles Steel, Stainless Steel and Cast Iron

Tangentially mounted for high cutting-edge strength, Sumitomo Electric Carbide’s PWS shoulder milling
cutter series is designed to handle a variety of materials, including steel and cast iron. It is available in
both coarse- and fine-pitch diameters ranging from 80 to 250 mm.
The shoulder mill features a two-step insert array structure that responds to deep cutting require-
ments, while breakers are optimized for edge sharpness and cutting ability. A 17-mm insert is said to
enable exceptional material removal, and its serrated design, created with high-precision molding
technology, provides stable milling, even in large overhang applications.
Sumitomo Electric Carbide Inc. /
847-635-0044 / sumicarbide.com

Hydraulic Expansion Toolholder

Suited for Rough Machining
The Schunk Tendo-ES is an extremely short hydrau-
lic expansion toolholder that enables the tool to be
clamped directly in the mounting taper so that the
tool shank is supported via the spindle. The result
is high holding forces for transferable high torques
and additional space in the machining area.
The 26.0-mm toolholder offers a run-out accura-
cy of less than 0.003 mm, and tools can be changed
in seconds with an Allen key. It is well-suited for
powerful and rough machining, HPC/HSC, drilling,
reaming, tapping, thread milling, and thread form-
ing. Benefits include brilliant surfaces, workpieces
with dimensional accuracy and long tool life. The use
of intermediate sleeves ensures complete flexibility.
The Tendo-ES is available for the SK 40 and
CAT 40 interfaces. Its clamping diameter is 20 mm
(3/4”), and standard Tendo sleeves can be used to
clamp smaller tool shank diameters with a balanc-
ing grade of G 2.5 at 25,000 rpm.
Schunk Inc. / 919-572-2705 /
us.schunk.com

moldmakingtechnology.com 81
Cutting Tools

Anti-Pull System Locks in

Collets, Cutters
Combining powerful gripping strength with a
patented locking key system and threaded cap,
Rego-Fix’s secuRgrip anti-pullout system is
designed to eliminate cutter slippage by locking
in collets and cutters when machining expen-
sive, tough materials in high-material-removal
applications.
The toolholder does not require expensive,
specially modified end mills, but rather makes
use of existing standard carbide or high speed
steel (HSS) end mill designs. The standard ground
notches found on most Weldon-type end mills
readily accept secuRgrip’s locking key insert for
speed and ease of assembly, Rego-Fix says.
The secuRgrip system can be used with Rego-
Fix PG 25 or PG 32 holders in all tapers, including Face Milling System Offers Variety of Insert Options
CAT, BT, TC, HSK, Capto and dual-contact Rego Designed for high flexibility in face milling, the Freedom Cutter system from
Plus. Licensed by Big Daishowa, Rego Plus prod- Tool Alliance’s Mil-Tec brand features a cutter body and three different insert
ucts are compatible with all Big Plus spindles. shapes, offering a variety of geometries, radius sizes, carbide substrates,
Rego-Fix Tool Corp. / 317-870-5959 / hones and coating options.
rego-fix.com The cutter body is precision-machined from hardened steel to exacting,
repeatable tolerances. Special pocket geometry allows for eight indexes on
the octagon and round inserts, and four indexes on the square insert. Metric,
coolant-through, cartridge-style, aluminum or other cutter bodies are available.
Tool Alliance / 714-898-9224 / toolalliance.com
Insert Geometry
Boosts Reliability,
Productivity in
Grooving Operations
Suited for radial grooving and groove turning in
the automotive and general metalworking industries,
the Walter Cut UD4 insert geometry is designed for maximum
process reliability, optimum chip formation, high productivity and
reduced tooling costs.
It features a multifunctional chip breaker design for greater chip control,
thanks in part to a double geometry that delivers a large application area.
The insert also offers a strong, zero-degree primary chamfer that strengthens
the cutting edge; a silver surface that makes for easy wear detection; and full
use of cutting edges.
According to the company, a standard PVD coating typically produces a
high rate of heat transfer into the cutting tool insert substrate, which leads
to higher wear rates. The UD4’s Tiger•tec silver PVD aluminum oxide coat-
ing is designed to produce less heat in the substrate, leading to longer tool Square Shoulder Mills Offer Flexibility in
life, reduced tool and tool-change costs, increased process reliability, and Tough Applications
increased productivity. The enhanced Turbo 10 series of square shoulder mills from Seco Tools
The main application area for the UD4 is grooving and groove turning on includes a variety of inserts, geometries, corner radii and helical cutters for
forged materials such as transmission components, gears and shafts. It is flexibility in applications involving tough materials. The insert range includes
said to work especially well in low-carbon steels where chip control is a par- both direct-pressed and ground insert alternatives with corner radii ranging
ticularly big challenge. Targeted workpiece materials are steel and cast iron. from 0.4 to 3.1 mm.
Walter USA LLC / 262-347-2400 / walter-tools.com/us Seco Tools Inc. / 248-528-5200 / secotools.com/us

82 MoldMaking Technology July 2014


End Mills Laser-Measured for Higher Accuracy
The Mold Maker line of end mills from the RobbJack group’s Crystallume divi-
sion are laser-measured, and the size, said to be accurate to 0.0001, is marked
on the packaging. According to Crystallume, this will enable customers to
manufacture electrodes to a higher accuracy.
Mold Maker tools offer features specifically for electrode and mold manu-
facturing. They have a 5x diameter-to-flute length with an extended shank,
and feature tolerances of +0.0000/-0.0005” (+0.000/-0.013 mm) for tools with
cutting diameters as large as 1/8” (3 mm) and +0.0000/0.0010” (+0.000/-0.025
mm) for larger tools. Shanks are held to a tolerance of -0.0001/-0.0002”
(-0.0025/-0.0050 mm) to ensure consistent and concentric gripping in shrink-
fit holders. The tools are also available necked for extended reach.
Crystallume / 408-653-1700 / crystallume.com
RobbJack Corp. / 916-645-6045 / robbjack.com
Cutting Tools Pages 61 to 84
8D Sizes Added to Coolant-Through
Carbide Drill Line
OSG Tap & Die has added 8D sizes to its Hy-Pro-Carb drill series, which also
includes 3D and 5D sizes. Suited for a variety of materials, the entire series’
point and flute geometry is designed to reduce thrust forces and chip size.
Higher feeds and metal removal rates may be achieved with the addition of
coolant-through capabilities, the company says. 3D and 5D sizes are available
in both solid and coolant-through models, and 8D in coolant-through only.
The drill series’ applied multi-layered TiAlN coating is said to resist thermo-
cracking from heat, thus improving wear resistance over conventional coat-
ings. According to OSG, the common DIN shank sizes not only improve rigidity,
but also reduce the number of toolholders needed to accommodate them.
OSG Tap & Die Inc. / 630-790-1400 / osgtool.com
moldmakingtechnology.com 83
Cutting Tools Cutting Tools Pages 61 to 84

Access video
VIDEO at end of article.

How to Optimize
Moldmaking
Milling Operations

By Troy Stashi
The lead angle of your cutter has a dramatic effect on not
only the chip that you generate, but also the cutting forces in
both the axial and the radial directions. All of this can affect

Images courtesy of Sandvik Coromant.

your overall productivity. There are many milling lead-angle
concepts on the market today, and each is designed to per-
form a specific task.
A square shoulder cutter, for example, produces the major-
ity of its cutting forces in the radial direction, making this
design best-suited for not only a square shoulder, but machin-
ing components where vibration could be an issue.
With the square shoulder cutter, you get no chip-thinning There are many milling lead angle concepts on the market today
effect. The programmed feed rate per tooth is exactly equal to and each is designed to perform a specifc task.
the actual chip thick-
ness. This makes a at very high feed rates. Using a very small lead angle—such as
square shoulder mill- 10 degrees—should be your first choice in machining with low
ing cutter a smart depths of cut.
choice for compo- As mentioned, with a square shoulder, you get no chip-
nents with thin sur- thinning effect. However, as the lead angle decreases, the chip
faces, in cases where thins. In fact, as you decrease the chip angle from square to 10
you have unstable degrees, the chip is thinned out to almost nothing. To achieve
fixturing; machines the proper chip thickness, increase your table feed.
with weaker spin- Milling cutters that have a very small lead angle are a smart
dles; and, of course, choice for high-feed machining with low cutting depths,
when you need to applications with long and weak setups, and effective hole
produce a 90-degree making using all three axes.
shoulder.
Face milling. The 90-degree
lead angle is com-
monly used in face milling because it can easily perform the CONTRIBUTOR
task, but it’s not usually the most productive or cost-effective Troy Stashi is industry and application specialist in automotive/milling
choice. A cutter with a 45-degree lead angle is a better choice for Sandvik Coromant.
for face milling.
VIDEO:
Also remember that, as the lead angle of your cutter Face Milling
decreases, so does the chip thickness, and you can increase short.moldmakingtechnology.com/facemill
your feed rate to compensate. This makes the 45-degree lead
angle cutter a smart choice for general-purpose face mill-
ing operations, reducing vibration on long overhangs and FOR MORE INFORMATION:
machining short chipping materials such as grey cast iron. Sandvik Coromant / 800-726-3845 / sandvik.coromant.com
Today, many companies are employing light cutting depths

84 MoldMaking Technology July 2014

 Pages 85 to 100

Machining
Pages xxx to xxx

Image courtesy of Hwacheon Machinery America.

moldmakingtechnology.com 85
 Is it possible to hold +/- .0002 on a bore in delrin? JBF1999
(29 new responses)

YOUR QUESTIONS. ANSWERED.

ACCESS THE COLLECTIVE KNOWLEDGE OF 101,000 MACHINISTS IN MINUTES.

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Ready for answers? Discover why our peer-driven
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Machining Pages 85 to 100

Hurco Companies, Inc. Toll-free: 800-634-2416

One Technology Way Email: info@hurco.com
P.O. Box 68180
Indianapolis, IN 46268 hurco.com

PRODUCTS/SERVICES
Hurco Leads 5-Axis Revolution
Hurco is leading the 5-Axis Revolution, a technology that is
becoming increasingly important for mold makers. While a vast
majority of mold makers have relied on 3-axis machining cen-
ters in the past, 3-axis machining has limitations, especially for
deep cavity molds or tall core molds.
Deep-cavity molds require long, skinny tools—to minimize
chatter and prevent tool breakage, you have to slow down the
feed rates. Often, you can’t achieve the quality of surface fin-
ish you need using 3-axis machining for mold work. For fine
finishing operations, especially on small diameter molds, 3-axis
machining can make the process more difficult than it needs
to be.
With simultaneous 5-axis machining, you can use shorter,
stouter tools, which means you can push faster with increased
feed rates. Using simultaneous 5-axis machining for mold work
means you can take heavier cuts and z-depths aren’t a problem.
All of this results in shorter total machining time.
Hurco has made 5-axis a priority. The last 10 years of
research and development has resulted in a broad line of 5-axis
machining centers and advanced 5-axis control features. Learn
more at hurco.com.

WEBSITE PRODUCT CATEGORIES

• Horizontal Machining Centers
• Lathes
• Machine Control Software
• Machine Controls
• Milling Machines
• Vertical Machining Centers

hurco.com

moldmakingtechnology.com 87
Machining Pages 85 to 100

Haas Automation, Inc. Phone: 805-278-1800

2800 Sturgis Road Toll-free: 800-331-6746
Oxnard, CA 93030 E-mail: haascnc@haascnc.com

HaasCNC.com

PRODUCTS/SERVICES
American-made Value,
Uncompromising Quality,
Worldwide Service
In 1983, Gene Haas founded Haas
Automation, Inc. to manufacture
the industry’s first fully automatic
programmable collet indexer.
Designed to increase production in Gene’s own machine
shop, the Haas 5C indexer was an instant success.
In 1988, Haas Automation achieved another industry
milestone by introducing the first American-built vertical
machining center (VMC) to sell for less than $50,000—a price
unheard of at the time. The Haas VF-1 sold for a published
price of $49,900, and quickly became the industry benchmark
for affordable CNC technology.
The Haas VF-1 still sells for less than $50,000, and Haas
Automation is one of the world’s leading manufacturers of
CNC machine tools, with an impressive line-up of more than
100 different products. Prices for all machines and options are
published online for all to see—something no other machine
tool builder can claim.
All Haas products are manufactured in the company’s
1-million-square-foot facility in Southern California, and
distributed through a worldwide network of more than
170 Haas Factory Outlets (HFOs). Each HFO
has complete showroom facilities, factory-
trained service personnel, extensive spare-
parts inventories, and fully stocked service
vehicles to provide the industry’s best service
and support.
From the start, Haas Automation has provided reliable,
affordable machine tool solutions to job shops and contract
manufacturers around the world. Extensive use of lean
manufacturing methods and just-in-time production practices
allows Haas Automation to produce high-precision CNC
products, while maintaining exacting quality and value-
based pricing.
At present, there are more than 150,000 Haas CNC machines
and 60,000 Haas rotary products in use around the world. In
2014, Haas Automation will build roughly 14,000 machines, with
around 60 percent of them going to international markets.

WEBSITE PRODUCT CATEGORIES

Our website is your one-stop shop
for information, specifications,
and pricing for every Haas
product. Explore all the options
and accessories available, then
use our Build-A-Quote system
to configure and price the exact
machine you want.
HaasCNC.com
• Vertical Machining Centers, up to Five-Axis
• Horizontal Machining Centers, up to Four-Axis
• Mold Machining Centers
• Five-Axis Machining Centers
• High-Speed Machining Centers
• Drilling & Tapping Machines, CNC
• Turning Centers, Horizontal, CNC
• Rotary Tables & Indexers, Single- and Dual-Axis

88 MoldMaking Technology July 2014

1 SETUP
4 SIDES
1/2 THE COST The Haas EC-400
Horizontal Machining Center
WITH MORE
Standard Features Include:
STANDARD • Side-mount tool changer • 1-degree pallet indexing
FEATURES . . . • 400 mm twin-pallet system
• 40 taper inline direct-drive spindle
The choice is simple

Haas Automation Inc. | www.HaasCNC.com | 800-331-6746 | Haas: The Lowest Cost Of Ownership.
Machining Pages 85 to 100

Doosan Machine Tools Phone: 973-618-2500

19A Chapin Road Fax: 973-618-2501
Pine Brook, NJ 07058
DoosanMachineToolsUSA.com

PRODUCTS/SERVICES
The range of mold making solutions from Doosan is among the industry’s
broadest. Doosan’s portfolio includes full 5-axis (with direct drive motors),
4+1 axis and 3 axis vertical machining centers, configured with linear roller
guides, box guideways or now even linear motors. Work capacity is equally
broad, within the Doosan range, beginning with small footprint 30 or 40
taper machining centers, all the way up to large gantry and boring mills for
automotive and aerospace applications.
Doosan’s latest addition to their machining center portfolio is the all
new FM200/5AX Linear 5-axis vertical machining center. This high-speed,
full contouring, 5-axis machining center is built upon a rigid bridge design.
The X, Y, and Z axes are driven by high precision linear motors, providing
extra high-speed acceleration/deceleration and cutting feederates. The 4th
and 5th rotary axes feature a direct drive motor, matching the high speeds
delivered in X,Y and Z. The spindle speed available on the FM200/5AX
Doosan’s all-new FM200/5AX Linear
Linear is a blistering fast 45,000 RPM, to achieve the highest surface
High-Speed, High-Precision 5-Axis
finish possible. Machining Center Featuring Linear Motors
Doosan Infracore Machine Tools designs, engineers and manufactures a
complete range CNC machine tools, including; vertical machining centers,
horizontal machining centers, turning centers, multitasking mill-turn
centers, boring machines, gantry mills and double column machining
centers. The company, a part of the larger Doosan Group, continues to
increase its competitiveness in global machine tools while establishing a
firm foundation to become the Global Leader in the machine tools industry,
assisting its customers in performance under pressure.

WEBSITE PRODUCT CATEGORIES

DoosanMachineToolsUSA.com • Five-Axis Machining Centers
is your portal to the industry’s
broadest range of metal cutting
• Vertical Machining Centers
solutions, which include over • Horizontal Machining Centers
300 models of CNC machine
• Boring Machines
tools. This site also contains
the latest news about Doosan • Mill-Turn Multi-Tasking Machines
innovations and how machine • Turning Centers
shops around the world use
our products and services to
perform under pressure.
DoosanMachineToolsUSA.com

90 MoldMaking Technology July 2014

Doosan Infracore America Optimal Solutions for the Future

s u re
r P res
n d e
ce U
a n
rm
erfo
Think of us as your pit crew, performing under pressure so you can, too.

P Contact Doosan today, so we can perform for you and win!

Parts Support on Demand

Productivity depends upon the optimal level of support
you receive for the life of your machine. So, while all
Doosan turning centers and machining centers are engi-
neered to be the most reliable and durable available, it’s
also comforting to know that Doosan Infracore America
stocks a wide variety of replacement parts right here in
the USA, backed by a team of experts on a mission to get
you the right parts when you need them.  

With Doosan, you can perform under pressure for your

customers, because that’s what our team is dedicated to
do for you. Think of us as your pit crew for productivity.
Why not contact Doosan today, so we can perform for
Booth S-8100, South Hall
you and win!

Doosan Infracore America Machine Tools

Corporate Office & Engineering Center Midwestern Technical Center
19A Chapin Road, Pine Brook, NJ 07058 - Tel. +1 973 618 2500 1701 F Howard Street, Elk Grove, IL 60007
dia.sales@doosan.com Western Technical Center
www.DoosanMachineToolsUSA.com 488 W. Meats Avenue, Orange, CA 93865
Machining Pages 85 to 100

Methods Machine Tools, Inc. Phone: 978-443-5388

71 Union Avenue
Sudbury, MA 01776 methodsmachine.com

PRODUCTS/SERVICES

YASDA
Yasda Precision of Japan, the most renowned and respected
manufacturer of machining centers in the world, is Methods
most recent partnership, and one we are significantly proud
of. Long known as the most precise machine built, it is the
machine of choice for machine tool builders around the world.
Yasda offers every capability to compete globally within the
aerospace and mold and die industries, and is unsurpassed in
precision and performance.
2009 marked Yasda’s 80th anniversary. Through the last
eighty years Yasda has constantly strived to make the best
machines in the world using our highly skilled engineers.
KIWA
KIWA MACHINERY CO., LTD. is a high quality machine tool
builder in Japan. Worldwide exports of their products to the
USA, Mexico and Canada began in 1981. Kiwa is a specialized
manufacturer producing 400mm and 500mm horizontals with
expandable ATC and APCs.
KIWA and Methods have been developing the expanded
line of Horizontals over the last two years and is excited to
showcase the final results by introducing the hew KMH Line of
Horizontal Machining Centers. Together with KIWA, Methods
now offers a full line of pallet size horizontals ranging from
300mm to 1250mm. KIWA—exceptional quality at a price that
should entice you to take a hard look at this new line.

WEBSITE PRODUCT CATEGORIES

• EDM’s- Wire, Sinker, Small Hole
• Graphite Electrode Machines
• Five-Axis Machining Centers
• High-Speed Machining Centers
• Horizontal and Vertical Machining Centers
• Lathes and Multi-Tasking Machines
• Bridge and Boring Mills
• Drilling/Tapping Machines
• Robots
• Pallet Changers, Loading/Unloading Systems
• Toolchangers
methodsmachine.com • Tooling and Accessories

92 MoldMaking Technology July 2014

 See us at booth # S-9119

Robotic Cell with

3 FANUC Robodrills

Nakamura-Tome WT-300 with FANUC gantry

robot and Schnaithmann workpiece carriers FANUC α-D21MiA5
JobShop Cell

Achieve Major Lead Time Reductions

for Low & High Volume Productions

A U TO M AT I O N BY

M ethods has designed and installed state-

of-the-art turnkey automation cells which
use VMCs, HMCs, lathes, and EDM machinery.
We are an authorized integrator of FANUC
robotics - including custom end-of-arm tooling
and on-site robotics training. From machine
tending to complete lights-out automation
with customized conveyor systems, integrated
vision systems, remote monitoring systems and
customized tooling and workholding, Methods
is the premier one-stop-shop for manufacturing
and productivity improvement.

WWW. METHODSMACHINE. COM

T ECHNICAL C ENTERS F ROM C OAST TO C OAST

B OSTON C HARLOT TE C HICAGO D ETROIT L OS A NGELES P HOENIX S AN F RANCISCO
978.443.5388 704.587.0507 847.783.6800 248.624.8601 714.521.2507 602.437.2220 510.636.1430

M ACHINE T OOLS ■ T URNKEY S OLUTIONS ■ A U T O M AT I O N C E L L S ■ P ARTS AND S ERVICE ■ T OOLING

Machining

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COMPANY Advertisers are listed in bold type See Ad 1 2 3 4 5 6 7 8 9 10
Absolute Machine Tools Inc., Lorain, OH, 440-960-6911 3 4 5 6 7 9 10
Chevalier Machinery, Sante Fe Springs, CA, 562-903-1929 3 4 5 7 10
DMG MORI, Hoffman Estates, IL, 847-593-5400 5 9 10
Doosan Infracore Machine Tools, Pine Brook, NJ, 973-618-2500 91 3 4 5 10
Dynamic International, Pewaukee, WI, 262-521-1100 3 4 8 10
Erowa Technology Inc., Arlington Heights, IL, 847-290-0295
FANUC Robotics America, Inc., Rochester Hills, MI, 248-377-7000
Fives Machining Systems, Hebron, KY, 859-534-4924 4 6 10
GF Machining Solutions, Lincolnshire, IL, 847-913-5300 5 9 10
Haas Automation, Inc., Oxnard, CA, 805-278-1800 89 4 6 10
Haimer USA, Villa Park, IL, 630-833-1500 1
Hardinge Inc., Elmira, NY, 607-734-2281 7 10
Hermann Schmidt Co. Inc., South Windsor, CT, 860-289-3347
Hurco Companies Inc., Indianapolis, IN, 317-293-5309 1, 87 10
Hwacheon Machinery America, Vernon Hills, IL, 847-573-0100 9 10
HYUNDAI WIA MACHINE AMERICA CORP., Itasca, IL, 6306255600 3 4 5 9 10
Kern Precision Inc., Webster, MA, 508-943-7202 4 6 7
Kitamura Machinery Of USA Inc., Wheeling, IL, 847-520-7755 4 5 9 10
Makino, Auburn Hills, MI, 248-232-6200 3 4 6 7 10
Mazak Corporation, Florence, KY, 859-342-1700 3 4 6 10
MC Machinery Systems, Inc./Mitsubishi EDM, Wood Dale, IL, 630-616-5920 103
Methods Machine Tools Inc., Sudbury, MA, 978-443-5388 93 3 4 5 6 9 10
Mighty USA Inc., Torrance, CA, 310-516-7478 4 6 7 10
Milltronics CNC Machines, Waconia, MN, 952-442-1410 3 6 10
Mitsui Seiki (USA) Inc., Franklin Lakes, NJ, 201-337-1300 3 10
Okamoto Corporation, Vernon Hills, IL, 847-235-3500 7
OKK USA Corp., Glendale Heights, IL, 630-924-9000 6 10
Okuma America Corporation, Charlotte, NC, 704-588-7000 7 10
Republic Lagun Machine Tool Co., Harbor City, CA, 310-549-1610 3 4 5 6 7 9 10
Single Source Technologies, Auburn Hills, MI, 248-232-6232 99 1 3 4 5 6 8 9 10
Sodick, Inc., Schaumburg, IL, 847-310-9000 5 9
Southwestern Industries, Inc., Rancho Dominguez, CA, 310-608-4422
System 3R USA LLC, Elk Grove Village, IL, 847-439-4888 5 6 7 9
Toyoda Machinery USA, Arlington Heights, IL, 847-253-0340 5 7 9 10
Tri-Tech Precision Products, Inc., Anaheim, CA, 714-970-1694 4 5 10
United Grinding, Miamisburg, OH, 937-859-1975 7
Yama Seiki USA, Inc., Chino, CA, 909-628-5568 4 5 9
Yamazen Inc., Schaumburg, IL, 800-882-8558 3 4 5 6 7 9 10
Yasda Precision America Corp., Elk Grove Village, IL, 847-439-0201 3 5 9 10
YCM Americas, Inc., Tustin, CA, 714-389-9988 5 9 10

For more supplier listings, go to moldmakingtechnology.com/suppliers

94 MoldMaking Technology July 2014

 Machining Pages 85 to 100

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11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 WEBSITE
12 17 19 20 22 24 25 26 27 absolutemachine.com
12 19 20 24 25 chevalierusa.com
11 12 17 19 20 24 25 dmgmori-usa.com
12 19 22 24 25 doosanmachinetoolsusa.com
12 19 25 27 dynamicintl.com
23 27 erowa.com
23 fanucrobotics.com
11 13 20 21 25 26 fvesmsi.com
19 21 23 25 gfms.com/us
12 19 25 haascnc.com
23 haimer-usa.com
12 19 25 hardinge.com
27 hschmidt.com
12 14 15 19 25 hurco.com
19 20 25 hwacheon.com
12 17 19 20 24 25 hyundai-wiamachine.com
17 18 19 23 25 kernprecision.com
17 19 25 kitamura-machinery.com
19 25 makino.com
12 17 19 23 25 mazakusa.com
11 19 25 26 mitsubishi-world.com
12 14 15 17 19 20 23 25 methodsmachine.com
12 19 25 mightyviper.com
12 14 19 25 milltronics.net
25 mitsuiseiki.com
okamotocorp.com
19 25 okkcorp.com
12 14 15 19 20 21 25 okuma.com
12 19 20 24 25 lagun.com
12 13 19 20 21 23 24 25 27 singlesourcetech.com
sodick.com
12 14 19 25 southwesternindustries.com
17 19 23 27 system3r.com
17 24 25 toyoda.com
15 18 19 20 25 5-axis.com
grinding.com
12 13 19 21 24 25 yamaseiki.com
24 25 yamazen.com
17 19 25 yasda.com
19 20 24 25 ycmcnc.com
Image courtesy of Unisig.

moldmakingtechnology.com 95
Machining
High-Precision VMC Offers Extended Travels
The NXV1680A vertical machining center from YCM offers extended travels
and high rigidity to meet the diverse machining requirements of job shops.
Models are available with 12,000- or 15,000-rpm, 40-hp spindles that include a
tool unclamping cushion to protect them and extend spindle bearing life. The
spindles also feature ceramic bearings with low inertia mass, low centrifugal
force and high rigidity for a low coefficient of thermal deformation; and high
precision helical springs for high dynamic balance and low vibration.
Roller guideways are standard on all the three axes, with six slider blocks
on the X axis, four guideways on the Y axis and a dual-driven Z axis with a zero
counterweight design. Finite element analysis also is used to ensure the best
mass arrangement and rib construction for constant stability under intensive
heavy-duty cutting.
The VMC is available with a 24- or 30-tool automatic tool changer equipped
with an absolute encoder for increased stability and speed. The inverter-
controlled system also prevents tool-change-speed variances under different
power supply frequencies. Other features include a five-auger chip evacuation
system with four augers along the Y axis and one along the X axis for efficient
chip removal.
YCM Americas Inc. / 714-389-9988 / ycmcnc.com
Modular Clamping System Reduces Setup Time
The FCS Modular Clamping System (Breyl) from Single Source Tech-
nologies allows diverse fixturing options for virtually any machining
sector by providing unrestricted access to five surfaces of the work-
piece and enabling operators to spend less time on setups and more
time on machining. The faster equipment and pallet changes facilitated
by this system have also translated into a more standardized work
process for improved part quality and consistency, the company says.
The system uses virtual design during the CAD/CAM stage of part
production to project a grid on the workpiece that calculates the
best way to attach the part for machining and chip evacuation. After
checking for possible interferences with other holes, it automatically
arranges the fixing seats based on the dimensions of the workpiece
and combination of pallets and clamping available.
Permanent reference points enable easy removal and reassembly of
the workpiece on the pallet or base gages to keep the zero reference
point locked in. This design facilitates engineering changes or part
repair, and the original mounting holes enable quick re-clamping at the
same point. No special equipment or standard maintenance is needed.
Single Source Technologies / 248-232-6232 /
singlesourcetech.com
96 MoldMaking Technology July 2014
Pg. 5
5-Axis HMCs Achieve High Material Removal Rates
The HBZ series five-axis horizontal machining centers from Handtmann use
high-performance spindles to achieve high material removal rates, particu-
larly for machining aluminum.
Offering material removal rates of more than 41 kg/min., the HBZ AeroCell
features a 156-kW, 30,000-rpm spindle and an integrated pallet changing sys-
tem. Pallet sizes range from 4 x 2 m to 7 x 2 m. X-, Y- and Z-axis travels measure
80 x 80 x 80 m. For increased productivity and flexibility, additional automated
solutions can be installed to link several machines together and store multiple
pallets in a single rack.
For smaller workpieces, the HBZ CompactCell series offers palette sizes of
2 x 1 m, 3 x 1 m and 4 x 1 m. It features an 81-kW, 30,000-rpm spindle, and XYZ
travels measuring 60 x 40 x 60 m. An automated pallet system that runs on
rails helps reduce downtime.
The HBZ Trunnion series is well-suited for machining steel and titanium
as well as aluminum. The three machines in this series are equipped with NC
rotary-swivel tables measuring 800, 1,200 or 1,600 mm in diameter. A rigid
machine design enables fast machining with spindles offering as much as
30,000 rpm and 1,010 Nm of torque.
Handtmann CNC Technologies / 847-844-3300 /
handtmanncnc.com
App Displays CNC Maintenance Reminders
Okuma America Corp. offers an app that displays scheduled maintenance and
inspection reminders directly on the CNC machine tool control without inter-
rupting programming, helping to minimize unplanned service and downtime.
Service recommendations can be displayed on a daily basis or intermit-
tently throughout the life of the machine, depending on the particular main-
tenance need. The app shows all of the maintenance tasks set for a specific
machine by the Okuma software department. If tasks cannot be completed on
a particular day, the user has the option to choose when to receive the next
reminder or can dismiss the warning.
Users can also opt for customized, periodic maintenance reminders that the
operator selects upon installation. Daily reminders include routine checks for
chuck/tailstock pressure and coolant/oil levels that can be programmed and
scheduled to appear based on user preference. Once the maintenance has been
performed, the operator checks off the tasks and minimizes the app.
Okuma America Corp. / 704-588-7000 / okuma.com
to 9 Machining Pages 85 to 100

Hybrid Machine Combines Laser Sintering, Milling

MC Machinery Systems has partnered with Matsuura Machinery Corp. to
introduce the Lumex Avance-25 metal laser sintering hybrid milling machine
to the North American market.
The machine combines metal laser sintering technology with high-speed mill-
ing technology to produce complicated parts using 3D data. Metal powders are
melted and sintered via laser, while surfaces are precisely milled at high speeds.
In die and mold applications, very complex geometries can be fabricated
in one piece with high accuracy, shortening lead time and reducing manu-
facturing costs compared to conventional methods, MC Machinery says. In
addition, 3D cooling channels can be incorporated into molds in the single
setup, increasing cooling efficiency and enabling high-cycle injection molding
VMC Designed for High Performance with improved quality and precision, reducing costs, and improving efficiency.
Hyundai WIA’s Value Master range of CNC vertical machining centers includes the The Lumex Avance-25 machines have been sold specifically in the die and
F650VM, which offers X-, Y- and Z-axis travels of 51.2” x 26.4” x 25”. Rapid traverse mold industry in Japan and Asia, but the company says they also are suited for
is 1,418 ipm (36 m/min.) in the X and Y axes, and 1,182 ipm (30 m/min.) in the Z axis. the aircraft, medical, automotive, aerospace, tool/die and job shop industries.
The bed, column and saddle of all Value Master series machines are designed They are capable of quick-turn production of custom parts, whether proto-
using finite element analysis to ensure powerful cutting and agility, and are com- types or small production runs.
posed of Meehanite cast iron to minimize deformation when performing heavy- Matsuura Machinery USA / 651-484-9698 / matsuurausa.com
duty cuts. The rigid bed is designed to absorb vibration for stable machining. MC Machinery Systems / 630-616-5920 / mcmachinery.com
All axes are driven by high-precision double-nut ballscrews for improved
positioning and repeatability with virtually no thermal growth during machin-
ing. All ballscrews are connected directly to the servomotors without gears
or belts, eliminating backlash. Rapid high-speed axis movement is achieved
by the use of linear motion guideways in all three axes, which reduces non-
cutting time and decreases machining time for greater productivity.
The F650VM also includes a 30-tool, side-mount, swing-arm toolchanger
that offers tool-to-tool change time of 1.5 sec. A shutter system separates the
toolchanger and magazine, and closes during machining to keep them clear
of chips and fluids. A 25-hp, 10,000-rpm Big Plus spindle provides dual contact
between the spindle face and the flange face of the toolholder, increasing tool
rigidity and productivity, and reducing runout. Ultra-precision, angular bear-
ings provide high-speed acceleration/deceleration for smooth machining at
high rpms, and the main spindle is said to deliver minimal noise and vibration,
even at the highest cutting speeds.
Hyundai WIA / 201-636-5600 / hyundai-wiamachine.com

Horizontal Boring/Milling Machine Offers Rigidity

The FBB-110/130 series horizontal boring and milling machines from Chevalier Machinery feature an
extra-rigid design for increased structural stability. The one-piece Meehanite cast iron machine base
includes four guideways on the Z axis for full table support with no overhang issues. It also offers large,
heavy-duty box ways on the X, Y and Z axes, and is coated with anti-friction material for consistent
accuracy and smooth movement. C3-grade ballscrews are used on all axes for high-precision positioning.
The machine’s table measures 63” x 55.1” and supports loads as heavy as 22,000 lbs. XYZ travel is 78.7”
x 78.7” x 59”, and W travel is 19.7” on the FBB-110 model and 27.5” on the FBB-130. The 35-hp, 50-taper,
large-diameter, cartridge-type, air-purged spindle runs with a ZF gearbox that generates a maximum of
1,220 foot-pounds at 600 rpm to overcome most tough-material cutting conditions. A spiral-type spindle
cooling system provides constant, all-around lubrication, preventing thermal deformation and prolonging
the life of the spindle, bearings and gears.
Chevalier Machinery / 562-903-1929 / chevalierusa.com

moldmakingtechnology.com 97
Machining
Horizontal Boring Mill Available with
Quill-, Ram-Type Spindles
The BL series horizontal boring mill from Yama Seiki includes two boring
spindle versions: the quill-type BL-S and the ram-type BL-FM. The BL-S machine
adapts with 22/26 kW (30/35 hp, cont. /30 min. rating) stepless variable speed
range with a two-step gear box ranging to 2,400 rpm. The spindle offers 120
mm (4.7”) of quill diameter with 600 mm travel, providing high rigidity and
stability for heavy cutting applications.
The BL-FM machine adapts with 22/25 kW (30/35 hp, cont. /30 min. rating)
stepless variable speed ranging to 6,000 rpm in a 480 x 480-mm section.
Spindle temperature is controlled by an oil spindle chiller.
Both machine versions feature a 40-tool automatic tool change system
located outside of the working area in order to keep coolant and chips off the
magazine and tool-change arm.
Yama Seiki USA Inc. / 909-628-5568 / yamaseiki.com
98 MoldMaking Technology July 2014
Pg. 5
Vertical Jig Boring/Milling Machine
Cuts Need for Hand Polishing
The Yasda YBM 640V3 three-axis CNC vertical jig borer from Methods Machine
Tools is designed for high-speed, precision boring and milling operations in
mold, die and complex-component manufacturing. With accuracy and rigidity
that virtually eliminates the need for hand polishing, the machine is said to
simplify moldmaking in industries such as aerospace, automotive, medical,
defense and more.
A reinforcement rib under the bridge provides increased rigidity and
minimizes vibration during acceleration and deceleration. The light weight
of the spindle head and saddle helps optimize machine efficiency, and the
hand-scraped alignment of through-hardened, 60-Rc box ways increases
mechanical accuracy. A rugged spindle enables a full range of machining, from
heavy-duty roughing to delicate fine finishing, while providing long tool and
spindle-bearing life.
The machine offers standard spindle speed as fast as 24,000 rpm and a 7/24
taper with No. 40 spindle taper hole. The table measures 27.5” x 17.7” (700 x
450 mm) and has a loading capacity of 661 lbs (300 kg). XYZ travel is 23.6” x
15.7” x 13.8” (600 x 400 mm x 350 mm). The YBM 640V3 also is equipped with a
100-tool automatic tool changer and a FANUC 31i-Model 5 controller.
Methods Machine Tools / 877-668-4262 / methodsmachine.com
High-Speed Machining Center Can Mill
Range of Materials
The M8Cube high-speed machining center from Datron Dynamics features
brushless, direct drives that provide fast acceleration, feed rates as fast as
866” per minute and short cycle times. A 3-kW, 40,000-rpm, liquid-chilled
spindle delivers greater horsepower for heavier machining, as well as the flex-
ibility to mill a wide range of materials. HSK-E 25 toolholders offer precision
and less than 1-micron runout.
The M8Cube is well-suited for precise, high- or low-volume production, as
well as industrial engraving and micro-drilling applications.
Datron Dynamics / 603-672-8890 / datrondynamics.com
to 9 Machining Pages 85 to 100

Horizontal Boring Mills Offer Long Spindle Stroke

Mitsubishi Heavy Industries’ MAF-E Series of table-type horizontal boring mills,
distributed in the U.S. by Yamazen Inc., features a boring spindle diameter
of 150 mm and an 800-mm extendable spindle stroke, said to be the longest
among the same class for medium-size workpiece machining. The mills’ struc-
tural rigidity enables high-speed, high-accuracy machining, Yamazen says. The
main spindle offers motor outputs of 30 kW, a spindle rotation speed of 3,000
rpm and a feed rate of 15 m/min.
Yamazen Inc. /
Machining Center Offers Greater Y-Axis Travel 800-882-8558 /
To satisfy mold customers who want more Y-axis travel without having to yamazen.com
jump to the larger footprint of the VMX64 machining center, Hurco offers the
VMX6030i, which provides 30” of travel in Y with travel of 60” and 24” in the
X and Z axes, respectively.
According to Hurco, the VMX6030i also includes many standard features
that competitive models offer as options, including a 40-tool swing-arm ATC,
a 12,000-rpm spindle and a 115-gallon coolant tank. The machining center also
has a larger table with a working surface of 66.14” x 30” inches and includes
a Hurco UltiMotion motion system, which is designed to reduce cycle time
and improve surface finish. As with all Hurco machine tools, the VMX6030i
is powered by the integrated Hurco control that supports both ISO/EIA and
conversational programming.
Hurco Companies Inc. / 317-293-5309 /hurco.com

CLAMP. DONE. RUN. Introducing FCS

clamping system from SST.
It’s that fast.

Learn how moving clamping setup time to

the CAD/CAM stage can drastically reduce
downtime at the point of production. Talk
to your SST representative about the latest
innovations from FCS clamping system.
Learn more at singlesourcetech.com/FCS
Visit us at IMTS 2014, Sept. 8-13, Chicago, IL
Booths E-5127 and W-2167

© 2014 Single Source Technologies.

moldmakingtechnology.com 99
Machining Machining Pages 85 to 100 Pg. 5

Access video
VIDEO at end of article.

How to Tackle
Sophisticated Molds

By Christian Spieker
Increasingly sophisticated molds require increasingly sophis-
ticated milling strategies and machine tool systems in order
to prevent internal stresses in the mold and to counteract
subsequent geometric distortions.

Images courtesy of Fooke USA Inc.

Using tools with small diameters ranging to 66 mm (2.59")
as well as shallow depths-of-cut ranging to 2 mm (0.078") can
dramatically reduce these internal stresses, eliminating the
need for posterior heat treatments and thereby shortening
delivery times. Selecting the right machine tool solution is
also key.
For the milling of tool steel, a linear machine tool system Roughing a workpiece made of tool steel 1.2312 (P20+S) with a
that uses such small-diameter roughing tools with feed rates roughing tool D = 66 mm (2.59“)
ranging to 6,000 mm/min. (236"/min.) as well as a high-fre-
quency milling spindle with an output of 63 kW (84.5 hp) and a
spindle torque of 300 Nm (221 foot-pounds) can achieve metal Considering that semi-finishing and finishing processes
removal rates of approxi- account for 70 percent of the milling of a mold, using such a
mately 0.75 l/min. (45.7 system can lead to huge productivity gains.
in3/min.). Machine tools with direct-drive linear motors for X, Y and
The use of a direct Z, and torque motors for C and A combined with the use of a
motor spindle and direct- direct motor spindle, offer a number of benefits. These ben-
drive linear motors for X, efits include the ability to increase productivity due to a more
Y and Z as well as torque dynamic performance regarding acceleration and jerk; control
motors for the rotary axis over the milling process by identifying wear and tear, and
of the milling head can breakage of cutting tools; automatic reduction of the feed rate
enable automatic moni- as the milling tool enters into the corners of the workpiece,
toring and identification and as a result, changes the interaction between the milling
of wear and tear as well as tool and the workpiece; and full control of the feed force dur-
cutting tool breakage. ing the milling operation.
Plus it will automatically
Finishing of a workpiece activate sister tools, if
for the automotive industry. needed. This control func- CONTRIBUTOR
tion—based on control- Christian Spieker is R&D manager at Fooke GmbH.
ling spindle torque and feeding force—is a feature to look for in
a machine tool system. VIDEO:
Using a direct-drive linear motor system also allows for Milling Precision, Speed and Surface Quality
increased dynamics over conventional drive systems. During short.moldmakingtechnology.com/fookemill
semi-finishing and finishing processes, which require less
spindle torque, these increased dynamics will drastically
reduce machining time. This can result in productivity gains FOR MORE INFORMATION:
of as much as 30 percent compared to conventional feed drive Fooke USA Inc. / 248-878-6536 / blorenz@fooke.us / fooke.us
concepts.

100 MoldMaking Technology July 2014

 Pages 101 to 108

EDM

Image courtesy of MC Machinery Systems/Mitsubishi EDM.

moldmakingtechnology.com 101
EDM Pages 101 to 108

MC Machinery Systems, Inc. Phone: 630-616-5920

1500 Michael Drive Fax: 630-616-4068
Wood Dale, IL 60191 Email: sales@mcmachinery.com

Mcmachinery.com

PRODUCTS/SERVICES
A World of Experience
Ingersoll Eagle As a part of the global Mitsubishi Corporation, MC Machinery
Gantry Eagle 1200
Systems draws from an extensive global source of support
and innovation. Mitsubishi Corporation employs 60,000
people around the world, across a wide spectrum of industries
including machine tools and controls, automotive, aerospace,
industrial machinery, elevator, energy, metals, chemical, food
and textile. This diversity, strength and stability trickles down
to MC Machinery Systems customers—who benefit from
Mitsubishi’s massive global R&D efforts and widespread
knowledge base.
EA12V Advance
Sinker EDM

Metal Working Success

MC Machinery customers get the best of both worlds: a single
source for a diverse arsenal of manufacturing technologies and
our expansive and knowledgeable support network.
Our expertise spans virtually every aspect of metalworking—
from simple fabrication to sophisticated, automated manufac-
turing cells. But it isn’t just the breadth of technology—laser,
waterjet, EDM, milling and press brake—that will bring your
MC Milling business to the next level; it’s our ability to identify, implement
DM1200G and support the right combination of those technologies.

WEBSITE PRODUCT CATEGORIES

Mcmachinery.com • Copper Electrodes • Milling Machines
• DI Equipment • Sinker EDM
• DI Resin • Small Hole EDM
• Electrode Holders • Vertical Machining Centers
• Electrodes • Water Jet Machines
• Filtration • Wire EDM
• Fixtures • Wires
• Fluids
• Graphite Electrodes
• Laser Cutting Machines

102 MoldMaking Technology July 2014

 Complex Geometry:
conformal cooling channels
for internal features
Variable Density:
gas venting/gas assist

Layer Machining:
deep slot machining
eliminates EDM
Profile Machining:
achieve high precision
finished parts

Cost Saving:
reduce mold

THINK construction time

DIFFERENTLY
BREAK THE MOLD WITH ADDITIVE MANUFACTURING
The LUMEX Avance-25, the world’s first and only metal laser
sintering hybrid milling machine, provides one-machine, one-process
manufacturing of complex molds and parts. It offers a 65 percent
reduction in manufacturing time and a 50 percent cost reduction
compared to traditional milling. CAD/CAM software is used to build
conformal cooling channels and vent points, which eliminates hotspots,
shrinkage and warpage—resulting in the most consistently accurate parts.

For more information, visit MCMachinery.com/additive

EDM
Machining

es

s
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ice s
t

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S er v

trod

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DI E
COMPANY Advertisers are listed in bold type See Ad 1 2 3 4 5 6
3D Pro’s Inc., Schaumburg, IL, 847-592-5559 4 6
Absolute Machine Tools Inc., Lorain, OH, 440-960-6911 4
Accu-Prompt Inc., Fridley, MN, 763-783-1020 4
B A Die Mold, Inc., Aurora, IL, 630-978-4747 4
Belmont Equipment & Technologies, Madison Heights, MI, 248-588-7011 1 2 3 4 5 6
Byrne Tool and Die, Inc., Rockford, MI, 616-866-4479 4
Chicago Mold Engineering Co., Inc., St. Charles, IL, 630-584-1311 4
Commercial Tool & Die, Comstock Park, MI, 616-785-5400 4
Copper and Brass Sales, Southfeld, MI 6
Current EDM Inc., Mountain View, CA, 650-966-9676 1 2 3 6
Dynamic International, Pewaukee, WI, 262-521-1100
EDM Network Inc., Sugar Grove, IL, 630-466-5588 3 5
EDM Sales and Supplies, Inc., Maple Grove, MN, 763-424-1189 1 2 3 4 5 6
Erowa Technology Inc., Arlington Heights, IL, 847-290-0295 5
Ezell Precision Tool Co., Clearwater, FL, 727-573-3575 4
Fortune International Inc., Somerset, NJ, 732-214-0700
Ganesh Machinery, Inc., Chatsworth, CA, 818-349-9166
GF Machining Solutions, Lincolnshire, IL, 847-913-5300 2 4
Graphel Corp., Waterbury, CT, 866-558-0111 1 4 5 6
Hirschmann Engineering USA, Inc., Schaumburg, IL, 847-468-9700 1 5
Industrial Molds, Rockford, IL, 815-397-2971 4
ITW Fluids North America, Glenview, IL, 847-657-5278
Keller Products Inc., Acton, MA, 978-264-1911
Kern Precision Inc., Webster, MA, 508-943-7202 1 4 6
Makino, Auburn Hills, MI, 248-232-6200
MC Machinery Systems, Inc./Mitsubishi EDM, Wood Dale, IL, 630-616-5920 103 1 2 3 5 6
McWilliams Sales & Service Inc., Mooresville, NC, 704-598-6616 1 2 3 5 6
Methods Machine Tools Inc., Sudbury, MA, 978-443-5388 93
Mold Craft Inc., Willernie, MN, 651-426-3216 4
Ohio Carbon Blank Inc., Willoughby, OH, 440-953-9302 1 6
ONA EDM USA, Addison, IL, 630-268-1635
Performance Alloys & Services Inc., Germantown, WI, 262-255-6662 1
Poco Graphite, An Entegris Company, Decatur, TX, 940-627-2121 107 6
Sodick, Inc., Schaumburg, IL, 847-310-9000 1 2 3 4 5 6
System 3R USA LLC, Elk Grove Village, IL, 847-439-4888 5
Toyo Tanso USA, Troutdale, OR, 503-661-7700 1 6
Transor Filter USA, Elk Grove Village, IL, 847-640-0273
Wisconsin Engraving / UNITEX, New Berlin, WI, 262-786-4521 1 4 6
Xact Wire EDM Corp., Waukesha, WI, 262-549-9005 4
YCM Americas, Inc., Tustin, CA, 714-389-9988

For more supplier listings, go to moldmakingtechnology.com/suppliers

104 MoldMaking Technology July 2014

 EDM Pages 101 to 108

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Wire

Wire
Sm a
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F il t r

F ix t

Flui

7 8 9 10 11 12 13 14 WEBSITE
10 3dpros.net
10 11 12 13 14 absolutemachine.com
accuprompt.com
badiemold.com
7 8 9 10 11 12 13 14 belmont4edm.com
byrne-tool.com
chicagomold.com
commercialtoolgroup.com
tkmna.thyssenkrupp.com
7 12 currentedm.com
13 dynamicintl.com
7 11 12 13 edmnetwork.com
7 8 9 10 11 12 13 14 edmsalesinc.com
erowa.com
ezellprecision.com
11 fortune-cnc.com
11 12 13 ganeshmachinery.com
11 12 13 14 gfms.com/us
9 10 11 graphel.com
8 9 11 12 13 hirschmannusa.com
industrialmolds.com
9 itwfuidsna.com
7 kellerproducts.net
10 kernprecision.com
9 11 12 13 makino.com
7 9 10 11 12 13 14 mitsubishi-world.com
7 9 10 11 12 13 14 mcwilliamsedm.com
11 12 13 methodsmachine.com
mold-craft.com
8 10 11 12 13 ohiocarbonblank.com
11 13 onaedmusa.com
moldstar.com
10 poco.com
7 9 11 12 13 sodick.com
8 11 13 system3r.com
10 11 13 ttu.com
7 9 transorflter.com
10 11 wisconsinengraving.com
xactedm.com
13 ycmcnc.com
Image courtesy of Delcam.

moldmakingtechnology.com 105
EDM Pg. 5

Wire EDM Expands Micromachining Capabilities

The UPN-01 ultra-precision horizontal wire EDM from Makino is well-suited
for micro-tolerance and fine surface finish applications. Designed with a
horizontal wire feed system, this sub-micron-level machine is said to provide
reliable unattended operation even when working with wire diameters as fine
as 0.00078” (0.02 mm). Its oil dielectric configuration also makes it suitable for
high-accuracy machining of carbide and other hardened materials.
The wire EDM features X-, Y- and Z-axis travels of 6.29” x 6.29” x 1.96” (160
x 160 x 50 mm), with additional U- and V-axis travels of ±0.27” (7 mm) each.
The UPN-01 will accommodate workpieces as large as 5.90” x 5.90” x 1.57” (150
x 150 x 40 mm) with a maximum payload of 17.63 lbs (8 kg), which includes
the toolholder.
The machine is also configured with an ultra-precision rotary C axis, which
is used for holding and indexing of the workpiece, and provides rotational
positioning accuracies of ±2 arcseconds. Due to the machine’s horizontal con-
figuration, the conventional work table configuration is replaced with a frame or
clamp-style tooling system that can also be automatically exchanged using the
optional 16-station automatic work changer system. Linear-Motor-Driven Wire EDMs
The UPN-01’s wire diameter ranges from 0.00078” to 0.00393” (0.02-0.1 mm) Improve Cutting Speeds
with a minimum start hole diameter of 0.00118” (0.03 mm). Reliable and consis- Sodick’s SL-G range of linear-motor-driven wire EDMs includes the SL400G and
tent automatic wire threading is achieved by using an air injection and suction SL600G. Both come with a 10-year positioning accuracy guarantee and feature
system. The maximum taper angle capability is ±6 degrees with a 0.00393” Smart Pulse generators, which are designed to reduce the number of cuts
(0.1-mm) wire diameter and 1.57” (40-mm) plate thickness. necessary to achieve the required accuracy and surface finish. The SL400G
Makino / 513-573-7200 / makino.com offers X-Y-Z travel measuring 15.75” x 11.81” x 9.84” (400 x 300 x 250 mm), while
the SL600G offers X-Y-Z travel of 23.62” x 15.75” x 13.78” (600 x 400 x 350 mm).
The machines’ Smart Pulse Wire control uses the Windows 7 operating
system and features a 19” multi-touch screen that can function as a traditional
screen or operate like a tablet. Screen layouts can be customized to suit the
operator’s working preferences.
Sodick Inc. / 847-310-9000 / sodick.com

EDM Graphite Grades

Balance Metal Removal,
Electrode Wear and
Surface Finish
Poco Graphite offers a variety of grades
of graphite that have been tailored for a
range of electrode applications. All have
been designed to offer a balance of metal
removal rates, low electrode wear and fine
surface finishes.
EDM-3, for example, is widely used for
production of plastic injection cavities.
Electrodes made from this grade are said
to excel in difficult and precision applications while providing predictable
results. This is an isotropic ultrafine-grain graphite that offers high strength
and wear and can be machined to thicknesses of 0.005 or less.
Poco Graphite also offers an online version of its EDM Technical Manual at
edmtechman.com that includes information on EDM technology and electrode
material selection.
Poco Graphite / 877-762-6336 / poco.com

106 MoldMaking Technology July 2014

to 9 EDM Pages 101 to 108

Wire EDM Interface Delivers Speed, Effciency and Ease of Use

AC Cut from GF Machining Solutions is designed to be a fast, efficient and as IGES and dxf.
easy-to-use human-machine interface (HMI), and provides a common language AC Cut also offers several automatic wire-EDM machining strategy func-
for the company’s entire Cut line of wire EDMs. The interface shares the same tions that are said to optimize both machine setup and performance, includ-
basic platform and functional layout as the company’s AC Form HMI for sinker ing wire recommendations through the GF Machining Solutions EDM Expert,
EDMs, enabling experienced wire EDM operators to seamlessly transition to reverse-cut and skimming-in-the-gap functionalities, and backward program
also running sinker EDM machines, and vice-versa. compatibility.
Based on a standard Windows platform, all functions in the AC Cut HMI, GF Machining Solutions / 847-913-5300 / gfms.com
including measurement and machining cycles,
are illustrated by graphics/icons for fast operator
understanding and ease of use. The interface also
features a “sequence” screen that automatically
organizes machining flow. Programming steps are
in logical and chronological order, and there is an
POCO EDM Tech Manual
on-board CAM system for quick programming at 4 decades as your technical partner
the machine from common part-file formats such

Sinker EDM Uses Less Graphite

The OPS-Ingersoll Eagle PowerTec EDM available
from Performance Machinery features “low-
wear” sinker EDM technology designed to burn
faster and use less graphite. In addition to graph-
ite cost savings, the machine offers reduced CNC
milling time, reduced programming time and the
use of fewer cutters for increased profitability,
Performance says.
The Eagle PowerTec EDM offers rigid, gantry-
design construction with the capacity to handle
large part sizes and a large toolchanger, aggres-
sive material removal with low wear on the
electrodes, and on-board programming with a
user-friendly conversational CNC controller.
Performance Machinery /
248-444-7981 /
performancemachineryllc.com
POCO’s EDM Testing program began in 1969 with the frst EDM
Technical Manual being published in 1974. This has since become a
highly sought after resource in both printed and CD-Rom versions.
Today the latest version of the EDM Technical Manual is available at
www.EDMTechMan.com. This valuable resource is now available as an
app for your iOS or Android capable device.

POCO® is a registered trademark

of Poco Graphite, Inc. iOS Device Android Device

moldmakingtechnology.com 107
EDM EDM Pages 101 to 108

Improve and
Simplify
Wire EDM

Image courtesy of Vero Software.

By Dean Kendall
An integrated CAD/CAM system
is recommended when using wire
EDM to machine high levels
of geometric complexity in molds.
The system’s design (CAD) tools
often compliment the manufacture This CAD/CAM software displays a four-axis wire
(CAM) tools, and they are developed specifically to meet and EDM operation for a complex mold core.
solve the needs and requirements of the industry using them.
A benefit of an integrated system is quick turnaround if
a change to the part’s design is required. The change can be tags can then be cut off individually in the morning when an
made in CAD, and then the CNC machine code is automati- operator is present.
cally regenerated by the CAM functions from within the single Because wire EDM is often a multiple-cut discipline that
software solution, often by the same person. requires the user to input dozens of parameters, another criti-
Although extremely accurate and reliable, the wire EDM cal feature of a CAD/CAM system with dedicated wire EDM
process itself is also relatively slow. Depending on its com- functionality is the user’s ability to select specific machine
plexity, a single mold plate technology (offset values, power settings, flushing registers,
One of the most important could require several days etc.) from within the system and apply the conditions to the
of machining to achieve the machining operations.
features of a CAD/CAM finished result. Some CAM systems integrate cutting databases, often
system for wire EDM One of the most impor- supplied by the machine tool manufacturer or imported from
tant features of a CAD/CAM the machine tool. These settings allow the user to select
is the ability to control
system for wire EDM is the criteria such as the required surface finish of the component,
the cutting order or ability to control the cutting which then enables the system to automatically choose the
strategy of programs order or strategy of pro- correct machining conditions from manufacturer-supplied
grams with multiple aper- data. Automating this process reduces the occurrence of user
with multiple apertures. tures (inserts, core pins, lift- input error, and therefore minimizes damage or scrapping
ers, etc.). This is because the of components.
wire passes right through The importance of a dedicated CAD/CAM solution for wire
the workpiece, thereby producing drop-out parts that are com- EDM cannot be overemphasized when dealing with automated,
pletely detached from the main billet of material. unattended and complex situations.
The process is so reliable that you can run the machine
without operator intervention for a long time. One way of CONTRIBUTOR
achieving this is to program a small tag on each aperture in the Dean Kendall is wire EDM product manager for Vero Software.
CAM system so that the slug does not fall out of the workpiece
and cause the machine to stop. To take it one step further,
you can select a CAM strategy that not only adds a small tag FOR MORE INFORMATION:
to each aperture, but also adjusts the cutting path to cut every Vero Software / info@verosoftware.com / verosoftware.com
aperture and leave its tag, possibly unmanned overnight. The

108 MoldMaking Technology July 2014

 Pages 109 to 114

Inspection/Measurement
Pages xxx to xxx

Image courtesy of Exact Jobboss.

moldmakingtechnology.com 109
Inspection/Measurement
Machining

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COMPANY Advertisers are listed in bold type See Ad 1 2 3 4 5 6
3D Systems Geomagic, Morrisville, NC, 919-474-0122 1 2 3 4 5 6
BLUM LMT Inc., Erlanger, KY, 859-344-6789 5 6
Brown & Sharpe, North Kingstown, RI, 401-886-2000 3 4 6
CAE Services Corporation, Batavia, IL, 630-761-9898
Capture 3D, Costa Mesa, CA, 714-546-7278 3 4 6
CGI 3D Scanning, Eden Prairie, MN, 952-937-2005 6
Delcam North America, Salt Lake City, UT, 877-335-2261 7 3 4 6
Direct Dimensions, Inc., Owings Mills, MD, 410-998-0880 1 2 3 4 5 6
Edmunds Gages, Farmington, CT, 860-677-2813 2
Exact Metrology Inc., Cincinnati, OH, 866-722-2600 2 3 4 5 6
FANUC Robotics America, Inc., Rochester Hills, MI, 248-377-7000
FARO Technologies, Inc., Lake Mary, FL, 407-333-9911 1 2 3 4 5 6
GKS Services Corp., Minneapolis, MN, 952-884-9648 1 2 3 4 5 6
Haimer USA, Villa Park, IL, 630-833-1500 1 4
Heidenhain Corp., Schaumburg, IL, 847-490-1191 2
Hexagon Metrology, Inc., North Kingstown, RI, 401-886-2000 3 4 5 6
JG&A Metrology Center, Detroit, MI, 519-962-5300 3 6
Konica Minolta Sensing Americas, Inc., Ramsey, NJ, 201-236-4300 1 2 3 4 5 6
Laser Design Inc., Minneapolis, MN, 952-884-9648 1 2 3 4 5 6
Lyndex - Nikken, Inc., Mundelein, IL, 847-367-4800 4
Mahr Federal Inc., Providence, RI, 401-784-3100 2 5
Marposs Corporation, Auburn Hills, MI, 248-370-0404 5
Micro-Vu Corp., Windsor, CA, 707-838-6272 4
Mitutoyo America Corporation, Aurora, IL, 630-820-9666 113 1 2 3 4 5 6
NextEngine, Santa Monica, CA, 310-883-1888
Nikon Metrology, Inc., Brighton, MI, 810-220-4360 1 2 3 4 5 6
NyproMold Inc., Clinton, MA, 978-365-4547
Optical Gaging Products (OGP), Rochester, NY, 585-544-0400 4
Perceptron, Plymouth, MI, 734-414-6100 1 2 3 4 5 6
REGO-FIX Tool Corp., Indianapolis, IN, 317-870-5959 1
Renishaw Inc, Hoffman Estates, IL, 847-286-9953 2 3
Resec Systems Inc., Bergenfeld, NJ, 800-394-6758 4
Roland DGA Corp., Irvine, CA, 949-727-2100
Starrett Company, Athol, MA, 978-249-3551 2 5 6
Steinbichler, Plymouth, MI, 734-927-1540 6
T2K - Tooling 2000, Redmond, WA, 425-558-0200
Verisurf Software, Inc., Anaheim, CA, 714-970-1683 3 4 6
Vision Engineering Inc., New Milford, CT, 860-355-3776 4 6
ZEISS Industrial Metrology, Maple Grove, MN, 800-327-9735 3 4 6
Zoller USA, Ann Arbor, MI, 734-332-4851 1 4 6

For more supplier listings, go to moldmakingtechnology.com/suppliers

110 MoldMaking Technology July 2014

 Inspection/Measurement Pages 109 to 114

ms
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7 8 9 10 11 12 13 14 WEBSITE
7 8 9 10 11 12 13 14 geomagic.com
7 8 9 11 blumlmt.com
7 8 11 hexagonmetrology.us
13 caeservices.com
7 8 9 11 12 13 14 capture3d.com
7 9 12 13 cgi3dscanning.com
8 9 delcam-na.com
7 8 9 10 11 12 13 14 dirdim.com
11 14 edmundsgages.com
7 8 9 10 11 12 13 14 exactmetrology.com
14 fanucrobotics.com
7 8 9 10 11 12 13 14 faro.com
7 8 9 10 11 12 13 14 gks.com
8 9 11 haimer-usa.com
7 11 heidenhain.us
7 8 9 hexagonmetrology.us
13 jgarantmc.com
7 8 9 10 11 12 13 14 konicaminolta.com/sensingusa
7 8 9 10 11 12 13 14 laserdesign.com
8 9 11 lyndexnikken.com
8 9 10 11 mahr.com
8 9 11 marposs.com
7 14 microvu.com
7 8 9 10 11 12 13 14 mitutoyo.com
7 8 12 nextengine.com
7 8 9 10 11 12 13 14 nikonmetrology.com
13 nypromold.com
7 8 9 14 ogpnet.com
7 8 9 10 11 12 13 14 perceptron.com
rego-fx.com
7 8 9 11 renishaw.com
7 14 resecsystems.com
7 12 rolanddga.com
8 9 10 14 starrett.com
7 8 9 12 13 steinbichler.com
14 t2k.net
7 8 11 12 verisurf.com
8 9 14 visioneng.us
7 8 9 11 14 zeiss.com/metrology
8 9 14 zoller-usa.com
Image courtesy of Marposs.

moldmakingtechnology.com 111
Inspection/Measurement
GUI Accesses Advanced Metrology Features
Blum LMT’s Gauging Guide is a graphical user interface (GUI) for use on Okuma
THINC Series controls that was developed to complement many of Blum’s core
metrology products, including lasers, tactile tool setters and workpiece probes.
Unlike some other metrology equipment GUIs, the Gauging Guide utilizes
Okuma’s THINC API, enabling operators to take advantage of the integration
between the two with a simple touch of the screen. The company says it devel-
oped the software after realizing that some of the advanced features of its
products were not being utilized due to the programming knowledge that was
required. This “clean” and straightforward GUI channels access to advanced
measuring capabilities in the macro programming software, Blum says.
Blum LMT Inc. / 859-344-6789 / blumlmt.com
Laser Scanner Suited for
Large-Range Applications
The Leica Geosystems ScanStation p20 laser scanner
available from Exact Metrology is designed for larger-
range applications as well as larger man-made objects. It
includes a “check and adjust” feature that that company says
can maintain the scanner’s accuracy without servicing.
The scanner offers a range of 120 m at 18-percent reflectivity, full 360 x
270-degree field-of-view and high scan speed of 1 million points/sec. It also
can operate in temperatures ranging from -20 to 50°C.
Exact Metrology Inc. / 866-722-2600 / exactmetrology.com
Scanning System
Performs Form, Profle
Measurement on
Complex Parts
Renishaw’s
Sprint machine tool scanning system is designed for fast, accurate
measurement. The system incorporates on-machine analog scanning
technology said to enable form and profile data capture from both
prismatic and complex 3D components. It also is designed to facilitate
automated process control with no operator intervention.
With scanning speeds as fast as 49 ft./min. (15 m/min.) and the
ability to measure 1,000 true 3D data points per sec., the system
provides workpiece measurement, inspection, adaptive machining
and on-machine process control, while optimizing machine utilization
and cycle time. It features an OSP60 scanning probe equipped with
an analog sensor with 0.1-micron resolution in three dimensions. The
sensor provides a continuous deflection output that combines with
machine position to derive the true location of the part surface.
Each Sprint application is enabled and supported by software
packages dedicated to specific industrial tasks, including toolkits for
on-machine data analysis that runs automatically in-cycle and pro-
vide measurement feedback to CNC machining processes.
Renishaw Inc. / 847-286-9953 / renishaw.com
112 MoldMaking Technology July 2014
CMM Offers Increased Accuracy
With a maximum error of (1.7+3L/1,000) microns, the Crysta-Apex S coordinate
measuring machine from Mitutoyo America is said to offer a higher accuracy
specification than other CMMs in its class, increasing the effective measuring
range at a given measurement tolerance.
Extreme rigidity helps the CMM maintain accuracy, the company says.
The Y-axis guide rail is integrated into one side of the granite surface plate.
Precision air bearings located on the bottom, front, rear and upper surfaces
of the X-axis slider minimize vibration and ensure stability, even during high-
speed, high-acceleration operation.
In addition, the machine’s drive offers maximum speed of 519 mm/sec.
and maximum acceleration of 2,309 mm/sec.2, resulting in higher throughput
for greater productivity, and lower total ownership and operating costs, the
company says.
The Crysta-Apex S also supports a range of probes that offer increased
capabilities, including the MPP-310Q scanning probe, which collects cloud point
data at speeds as fast as 120 mm/sec. Other probes suited for screw-depth,
ultra-small-diameter and non-contact measurement are also supported.
Mitutoyo America Corp. / 888-648-8869 / mitutoyo.com
Inspection Software Offers More Reporting Options
With model-based GD&T inspection technology at its core, the seventh genera-
tion of Verisurf X computer-aided inspection, reverse engineering and assem-
bly guidance software supports more options for reporting and presenting
data, including Microsoft Word, PowerPoint and Adobe 3D PDF viewer.
Verisurf X7 also offers variety of application features designed to enhance
productivity and improve reporting, data management, measuring and more.
It includes integrated access to InspectionXpert software for automating the
creation of drawing-based AS9102 first-article inspection and reporting, and
also integrates with CM4D statistical process control software. Other features
include customizable data trees, controls for repeatability testing and laser
scanner measurements, best fit in auto inspection, an MBD manager capture
view tool, auto hole axis tool, smart point tools for auto alignment targets, and
improved scaling of features and alignments.
Verisurf Software Inc. / 714-970-1683 / verisurf.com
 Inspection/Measurement Pages 109 to 114

Probing System Features Radio Transmission Capability

The Marposs Mida WRS probing system with radio transmission includes a bore plug gage, tool setter, spindle touch probe,
receiver and remote control for programming. It offers an applied transmission frequency band of 2.4 GHz, spherical trans-
mission characteristics and a 15-m operating range, making it both flexible and powerful, the company says. The system auto-
matically searches for the best signal among the 74 available radio channels in order to ensure optimum communication con-
ditions between the probe and the receiver. Additional sub-channels enable the use of multiple probes on the same machine
by means of a simple NC selection code. The WRS receiver interface features remote programming capability, enabling the
user to easily program and check the system. The
system’s modular design allows the use of differ-
ent probes with repeatability of as much as 0.5
micron at 2 Sigma, as well as increased resistance
against coolant and chips, Marposs says.
Marposs Corp. / 248-370-0404 /
marposs.com

Miniature Infrared Touch Probe

Can Access Tight Spaces
Designed to address the needs of miniature
machining centers, Hexagon Metrology’s IRP40.50 View a Ko-ga-me
CMM in Action
infrared touch probe is well-suited for inspection
in tight spaces. The small, self-contained wireless
CNC probe features a diameter of 25 mm, a length
of 44.2 mm without shank and stylus, and a prob-
www.mitutoyo.com/kogame
ing force of 0.7 N (XY), enabling measurement of
small and delicate workpieces. With the shank
and stylus included, the IRP40.50 is slightly larger
than a standard USB stick. Looking for a fast, extremely compact, versatile
Typical applications for the probe include micro- metrology product?
manufacturing in the firearms, medical, dental, The MACH Ko-ga-me is essentially a compact CMM – a perfect solution. This agile
additive manufacturing and electronic industries, measuring system provides flexibility of operating temperature and production
or virtually any manufacturing that involves small environments through thermal compensation and factory mounted high precision
scales. Mounted on any rigid frame, including machine tools, the MACH Ko-ga-me
parts with complex geometries and tight toler- provides CMM capabilities without the space requirements of a full sized machine
ances, the company says. The stylus threading is M2 and in-process measurement without involving set-up breakdown.
but enables probe cycles at speeds as fast as 2,000 • High-speed measurements for production environment
mm/min. According to the company, even with its • Extremely small footprint - perfect for automated cells
small profile, the IRP40.50 has proven high data • Ideal for single feature inspection
• Usable with scanning and point-to-point probes
rate infrared transmission, guaranteeing that only
• Measuring range up to 120 mm
the system’s own signals are processed, and dis- • Resolution of 0.02 μm and a measuring accuracy of (2.0+0.5L/1000)μm
turbances caused by extraneous light are ignored.
For more information visit us online at www.mitutoyo.com
The probe works with PC-DMIS NC-Gage v2.1 soft- or scan the QR code to view a short video demonstration.
Ko-ga-me
ware, which is said to simplify CNC probe opera-
mitutoyo America corporation | 1-888-mitutoyo | www.mitutoyo.com
tions in easy-to-follow, user-friendly instructions.
c m m • v i s i o n • f o r m a n d f i n i s h • p r e c i s i o n t o o l s a n d i n s t r u m e n t s • d ata m a n a g e m e n t
Hexagon Metrology Inc. / 401-886-2000 /
hexagonmetrology.us

moldmakingtechnology.com 113
Inspection/Measurement
Selection Criteria for
Laser Scanning Technology
By Alex Lucas
Retrofitting CMMs and articulated arms with new laser scan-
ners is an option for many manufacturers, and with the right
choices in scanning and software technology, mold manufactur-
ers can achieve several advances in their inspection and mea-
surement processes. These advances include:
Measurement coverage. Where many touch probes might
achieve input rates of 1 point per second, laser scanning stripes
can range from 50 to 200 mm (1.97 to 7.87 inches) in width and
scan tens of thousands of data points per second.
Speed. Molds, production dies, complex 3D castings, turbine
blades, cell phones and plastic parts can be scanned in a matter
of minutes with laser scanning.
Offline and easy-to-understand reporting. Reserving your
CMM or articulated arm for measuring, inspecting and trans-
ferring data to PC-based reporting software can significantly
reduce inspection time and speed time to market.
Quick, simple, cost-effective retrofits. A range of laser scan-
ning options are compatible with many existing CMM and
articulated arm setups. Often retrofits can be accomplished in a
matter of hours.
Ability to automate. Integrated software packages are avail-
able that can collect data, measure, compare scanned data to
CAD models, and generate reports with both visual repre-
sentations and tabular data into a single automated process.
Incorporating color-coded visuals and tabular data can speed
approval processes and make sharing information easier.
Cross scanning. New technologies such as cross scanning
combine multiple scanners and digital cameras for scanning
complex parts and features without re-orientation.
Many choices exist for CMM-based laser scanning. For entry
level, there are single-stripe laser scanners that provide roughly
a 50-mm stripe width, generate 20-25 stripes per second and
input approximately 20,000 points per second while maintain-
ing an error tolerance of 20 to 25 microns. For more demanding
inspection tasks, use a laser scanner that has a 60-mm stripe
width while scanning at 75 stripes per second and can maintain
an error tolerance of 9 microns. Scanners are also available with
smaller fields of view for digitizing small, detailed objects with
higher point densities and tolerances as low as 4 microns.
For scanning large objects, laser scanners are available in
hand-held models or for attaching to articulated arms, mak-
ing mobile scanning easier. Depending on the type of scanner,
stripe widths can vary between 50 and 200 mm, and digital
114 MoldMaking Technology July 2014
Inspection/Measurement Pages 109 to 114
Image courtesy of Nikon Metrology.
cameras capture more
than 1,000 points per
stripe. This provides
optimum resolu-
tion for efficiently Retroftting CMMs or articulated arms
scanning freeform with laser scanners is one affordable option
surfaces and features. many moldmakers should be considering.
Cross scanners are
also available that incorporate multiple scanners and multiple
cameras for measuring or reverse engineering large parts.
A former challenge with laser scanning was scanning highly
reflective surfaces that would necessitate spraying the object
with a matte spray coating to eliminate obtaining reflective
data and other extraneous noise. Today’s laser scanners feature
automatic real-time adjustment of sensor settings for each
individual point along the laser stripe, effectively handling
highly reflective surfaces or those with varying colors.
Software compatibility is another important point to con-
sider. Laser scanning can input tens of thousands of points
per second, so effective inspection software should be able
to handle a large volume of inspection data (as many as 100
million points) and provide the following tools: automated
feature detection algorithms; full part comparison to CAD
or STL files; complete set of 2D and 3D features; geometric
dimensioning and tolerancing (GD&T) ability; specialized mea-
suring capability, such as wall thickness, flush and gap, and
directional comparisons; dedicated inspection modules; and
off-line modules that enable users to employ CMMs or articu-
lated arms for inspection, and personal computers for creating
or modifying reports and models.
Every manufactured part has its own range of inspection
or reverse-engineering issues, and advances in laser scanning
technology can address these challenges.
CONTRIBUTOR
Alex Lucas is business development manager for scanning products at Nikon
Metrology Inc.
FOR MORE INFORMATION:
Nikon Metrology
jeffrey.bourque@nikonmetrology.com / nikonmetrology.com
 Pages 115 to 126

Mold Maintenance, Repair & Surface Treatment

Pages xxx to xxx

Image courtesy of Wisconsin Engraving.

moldmakingtechnology.com 115
Mold Maintenance, Repair and Surface Treatment Pages 115 to 126

Alliance Laser Phone: 847-487-3999

275 Industrial Dr. Fax: 847-487-2945
Wauconda, IL 60084
alliancelasersales.com

PRODUCTS/SERVICES
Alliance Laser offers in-house laser welding and laser engraving
services that are second to none. We have also partnered with the
leaders in the mold finishing industry to ensure we are providing
our customers the very best solutions. Polishing, nickel plating,
chrome plating, mold maintenance and repair are just a few of the
areas that we can help you achieve success in your next project.

Specifically Engineered for Industry Toolmakers.

The NGRV51 Laser Engraver is the ideal tool for a wide range
of laser marking and engraving applications which require a
permanent mark on a wide range of materials. Cutting edge
features such as a programmable X, Y, Z movement table, color
marking technology, the ability for production or single run
applications, and a digital camera with a 19" HD viewing display
for precision accuracy. 15x more energy efficient lowering cost
of use. Virtually maintenance free eliminating downtime and
the expense of costly replacement parts. Superior beam quality
surpassing all conventional lamp and diode pumped systems.
Small spot size allowing for accurate and graphic reproduction.

WEBSITE PRODUCT CATEGORIES

• Coatings, Plating Services
• Laser Welding Equipment
• Mold Maintenance & Repair Services
• Polishing Services
• Welding Services
• Wires

Visit us online at alliancelasersales.com to learn more about

the products and services we offer.
alliancelasersales.com

116 MoldMaking Technology July 2014

Mold Maintenance, Repair and Surface Treatment Pages 115 to 126

OR Laser Toll-free: 800-815-4412

1420 Howard St. Fax: 847-593-5752
Elk Grove Village, IL 60007
or-laser.com

PRODUCTS/SERVICES

The NEW ECO Laser
Welding System
Now available from 100 watts to 200
watts with the new robust joystick for
industrial environments and offering
teach mode capability. The rising demand
for inexpensive laser welding solutions
motivated us to develop an affordable
introduction to Laser Welding. Our ECO
Laser System is Small and Compact yet
Powerful and Ergonomic. With simple
controls the ECO Laser can be quickly
readied for continuous usage and profes-
sional results.
The NEW EVO Mobile Diode Line
Diode-pumped laser systems are char-
acterized by their 15 times higher energy
efficiency. With the DIODE LINE con-
cept, OR Laser enters a new dimension
in the field of laser material processing.
Through the use of diode-pumped laser
systems, this new concept impresses by
offering a number of key advantages
over conventional flash lamp pumped
systems. With very high efficiency of
over 40 % (electrical to optical) and
Maintenance-free operation. Visit our
web site to learn more.
The NEW LPX System
The LPX Laser sets new standards and is
the ultimate solution for all imaginable
marking and engraving tasks. The Minimal
spot width is 50 μm in a focused status at
a pulse energy of max. 1.5 mJ. The highly
dynamic and precise laser processing
station is equipped with a linear actuator
for three Axes, each axis reaches an
acceleration of 1 m / s2 at maximum speeds
of 30 m/min. The solid granite construc-
tion along with a portal construction and
direct position sensor system provide a
maximum of precision with a processing
area of 24" x 24".

WEBSITE PRODUCT CATEGORIES

Visit our Web Site for more • Laser Welding Equipment
information on: Products,
• Mold Maintenance & Repair Services
Services, Digital Brochure
Downloads, Accessories, • Welding Services
World Wide Partners and
Detailed Descriptions of
Training, Service, Production
and Repair solutions.
or-laser.com

118 MoldMaking Technology July 2014

 the better way to work

What you need to know about laser...

...for more information visit us @ www.or-laser.com

EVO MOBILE

ECO LASER

IQ LASER

LPX Laser

T E C H N O L O G Y

O.R. Lasertechnology Inc. · Tel.: +1 847-593-5711 · sales@or-laser.com · www.or-laser.com

Mold Maintenance, Repair and Surface Treatment
PRODUCTS/SERVICES
Open WorkSpace Welding
Workstation—7800 Series
LaserStar’s 7800 Series manual welding
systems are ideal for a variety of com-
mon spot and seam welding applications
including plastic injection mold, dies
and tooling repair, complex electronic
components, high-precision industrial
assemblies, pressure-sensitive hermetic
laser sealing, and other unique indus-
trial applications.
LaserStar offers multiple power levels
(60 watt - 200 watt). Made in USA.
WEBSITE
laserstar.net
120 MoldMaking Technology July 2014
LaserStar Technologies Corporation
One Industrial Ct.
Riverside, RI 02915
FiberCube Laser Engraving
System—3800 Series
The FiberCube® is a compact, turnkey
marking, engraving and cutting system
that offers the benefits of a non-contact,
abrasion-resistant, permanent laser mark,
engraving, or cut onto almost any type
of material. High-speed, high precision
FiberCube systems are ideal for a wide range
of integration applications including flat
surfaces, advanced integrated XYZ motion
for step-and-repeat laser marking or coor-
dinated rotary motion for seamlessly mark-
ing around a circumference. Made in USA.
PRODUCT CATEGORIES
• Laser Engraving
• Laser Welding Equipment
• Mold Maintenance & Repair Services
• Surface Treatment
• Welding Services
Pages 115 to 126
Phone: 401-438-1500
Fax: 401-434-7260
laserstar.net
Universal Jig Welding
Workstation—7700 Series
LaserStar’s 7700 Series manual welding
Systems are ideal for a variety of com-
mon spot and seam welding applications
including plastic injection mold, dies
and tooling repair, complex electronic
components, high-precision industrial
assemblies, pressure-sensitive hermetic
laser sealing, and other unique indus-
trial applications.
Multiple power levels (100 Watt - 200
Watt) available. Made in USA.
 Manufacturer of Advanced Laser Sources & Systems: Welding - Marking - Cutting

The Closest Thing to a Perfect Weld

Mold Repair Laser Welding Systems
Today’s precision welding marketplace specializing in
laser spot welding or laser seam welding applications
have a wide range of new technologies available
to enhance their ability to provide the highest
level of quality, craftsmanship, and service to their
clients. LaserStar’s 7800 Series Manual Welding
Systems are ideal for a variety of common welding
applications including plastic injection mold, dies and
tooling repair, complex electronic components, high-
precision industrial assemblies, pressure-sensitive
hermetic laser sealing, and other unique industrial
applications for the automotive, aerospace, aviation,
computer, medical device, mold repair, and consumer
product industries.

Many materials can be laser welded including 300

and some 400 series stainless steel, mild steels,
nickel and nickel alloys, aluminum and aluminum
alloys, titanium, precious metal alloys (gold, silver, and
platinum), etc.

LaserStar ofers multiple power levels (60 Watt -

200 Watt) to meet a wide variety of application
requirements.
7800 Series
Laser Welding System
with Cockpit Joystick Control

FOLLOW LASERSTARTV
MADE IN THE USA

W W W. L A S E R S TA R . N E T
RI LaserStar Center (Corporate Office) FL LaserStar Center CA LaserStar Center
One Industrial Court 8615 Commodity Circle, Suite 19 145 North Sierra Madre Blvd, Suite One
Riverside, Rhode Island 02915 USA Orlando, Florida 32819 USA Pasadena, California 91107 USA
401-438-1500 • Fax: 866-516-3043 407-248-1142 • Fax: 866-708-5274 213-612-0622 • Fax: 866-347-0934
Email: ri.sales@laserstar.net Email: fl.sales@laserstar.net Email: ca.sales@laserstar.net
Mold Maintenance, Repair & Surface Treatment

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COMPANY Advertisers are listed in bold type See Ad 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Alliance Laser Sales Inc., Wauconda, IL, 847-487-1945 117 2 13
Armoloy of CT, Inc., Bristol, CT, 860-583-7088 2 3 6
Bales Mold Service, Downers Grove, IL, 630-852-4665 2 3 10
Blue Wave Ultrasonics, Inc., Davenport, IA, 563-322-0144 1 15
BORIDE Engineered Abrasives, Traverse City, MI, 231-929-2121 1
Branson Ultrasonics Corp., Danbury, CT, 203-796-0400 1
Brush Research Manufacturing Co., Inc., Los Angeles, CA, 323-261-2193 9
Caliber Engraving & Development, Brea, CA, 714-671-9495 8
Cold Jet, LLC, Loveland, OH, 513-831-3211 1 9 14 15
CVD Diamond Corporation, London, ON, 519-457-9903 3
Duro-Chrome Industries, Wauconda, IL, 847-487-2900 2 8 10 13
EAS Mold & Die Change Systems Inc., Menomonee Falls, WI, 262-783-7955
ENGIS Corporation, Wheeling, IL, 847-808-9400 1
Extrude Hone Coporation, Irwin, PA, 724-863-5900 10
Fisa North America, Elk Grove Village, IL, 847-299-8400 1 15
Gesswein & Company, Bridgeport, CT, 203-366-5400 1 4 7 13
High Tech Laser and Polishing, Lee’s Summit, MO, 815-525-9800 8
ITW Fluids North America, Glenview, IL, 847-657-5278 1
Kern Precision Inc., Webster, MA, 508-943-7202 7 8 10
LaserStar Technologies Corporation, Riverside, RI, 401-438-1500 121 7 13
Lewis Bawol Welding, Erie, PA, 814-838-1074 8
Micro 100 Tool Corp., Meridian, ID, 208-888-7310 76 8
Mold Polishing Co., Garwood, NJ, 908-518-9191 10
One Source, Wauconda, IL, 847-487-2900 117 13
OR Laser, Elk Grove Village, IL, 847-593-5711 119 13
Oerlikon Balzers Coating USA Inc., Schaumburg, IL, 847-844-1753 3
Polymer Cleaning Technology, Inc., Hillsborough, NJ, 908-281-0055 1 15
Precision Laser Technology, Rochester, NY, 585-458-6208 128 8
Rocklin Manufacturing Co., Sioux City, IA, 712-255-7957 2 3 7
Rofn-Sinar, Inc., Plymouth, MI, 734-455-5400 7 13
RUD-Chain, Inc., Hiawatha, IA, 319-294-0001
Slide Products, Inc., Wheeling, IL, 847-541-7220 1
Starrett Company, Athol, MA, 978-249-3551
Sulzer Metco Inc., Amherst, NY, 716-270-2228 2 3
Thermal-Tech Systems, Inc., West Chicago, IL, 630-639-5115 1 15
ToolingDocs, Ashland, OH, 419-281-0790 15
TRUMPF Inc., Farmington, CT, 860-255-6000 13
United Tool & Mold Inc., Easley, SC, 864-859-8300 13
Wisconsin Engraving / UNITEX, New Berlin, WI, 262-786-4521 8
Xebec by Deburring Technologies, Huber Heights, OH, 800-306-5901

For more supplier listings, go to moldmakingtechnology.com/suppliers

122 MoldMaking Technology July 2014

 Mold Maintenance, Repair & Surface Treatment Pages 115 to 126

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16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 WEBSITE
18 25 39 alliancelasersales.com
armoloyct.com
19 25 29 39 balesmold.com
29 38 bluewaveinc.com
19 24 25 29 borideabrasives.com
bransonultrasonics.com
17 24 brushresearch.com
36 caliberengraving.com
coldjet.com
cvddiamond.com
18 25 39 duro-chrome.com
20 34 easchangesystems.com
17 24 37 moldpolishing.engis.com
17 25 extrudehone.com
29 38 fsa.com
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18 24 25 36 39 htlaser.com
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17 25 36 kernprecision.com
laserstar.net
18 39 lewisbawol.com
micro100.com
24 25 36 39 moldpolishing.com
39 thenewonesource.com
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oerlikon.com/balzers/us
polymercleaning.com
36 39 precisionlasertech.com
35 39 rocklinmanufacturingco.com
rofn.com
30 rudchain.com
19 29 slideproducts.com
19 starrett.com
sulzer.com
18 28 29 thermal-tech.com
18 toolingdocs.com
us.trumpf.com
18 23 28 36 39 utminc.com
18 25 36 wisconsinengraving.com
24 25 deburringtechnologies.com
Image courtesy of Dickten Masch Plastics.

moldmakingtechnology.com 123
Mold Maintenance, Repair & Surface Treatment
Open Laser Welding Workstation
Accommodates Many Applications
LaserStar Technologies’ 7800 series open laser welding workstation is
designed for general welding of large parts, tool and die repair, injection
mold repair, and other applications. It can perform deep, seam, contour and
complex-pattern welding, and is well-suited for use in the automotive, aero-
space, aviation, computer, medical device, mold repair and consumer product
industries.
A variety of materials can be laser-welded, including 300 and some 400
series stainless steel, mild steels, nickel and nickel alloys, aluminum and alu-
minum alloys, titanium, precious metal alloys (gold, silver and platinum), and
more. Multiple power levels ranging from 60 to 200 W are available.
LaserStar Technologies Corp. / 401-438-1500 / laserstar.net
Laser Welding System
Engineered for Mold Repair
The Vision Unixx II laser welding system available from Alliance
Laser Sales was specifically engineered for the mold repair industry,
featuring an adjustable, removable base for easy application to a
variety of job sizes. A wide X-Y travel range enables the operator to
work on large areas of the part without having to reposition it. The
machine also offers high-grade automated control, laser movement
synchronization, laser-marking technology and a teach-in program
that provides automatic driving of complex 3D geometries.
Alliance Laser Sales Inc. / 847-487-1945 /
alliancelasersales.com
124 MoldMaking Technology July 2014
Electric Lab Oven Preheats Molds
The No. 969 electrically heated 200°C (~392°F) laboratory oven from Grieve
Corp. currently is used for preheating 15-lb molds. With workspace dimen-
sions of 12” x 10” x 10”, the oven features 800 W installed in Incoloy-sheathed
tubular elements for heating, while gravity convection provides the airflow
to the load.
This specially modified oven features 1” insulated walls, an aluminized
steel interior, stainless steel exterior with a #4 brushed finish, heavy-duty
door latch, reinforced door hinge, shelf supports bolted through the oven
walls to support the load at a double shelf height and an adjustable fresh air
inlet damper at the oven bottom to control the amount of fresh air entering
the chamber.
For added accuracy, the oven’s temperature control shaft is recessed and
slotted to avoid a set-point change.
Grieve Corp. / 847-546-8225 / grievecorp.com
Laser Marking Workstation
Has Compact Footprint
The compact FOBA M1000 manual laser
workstation is designed for laser marking
of small- to medium-sized metallic and
plastic components and workpieces, as
well as batches of parts. In addition to the
automotive, tool and metal industries, the
universal marking machine is well-suited
for a variety of medical, plastic and con-
tract manufacturing applications.
Designed for both benchtop and cart-
mounted operation, the portable marking
station is equipped with a programmable
Z axis for positioning the marking laser, a 450 x 250-mm work table and a wide-
opening lift door. The complete workspace offers high visibility and is easily
accessible from three sides. In order to cover a broad application range, various
fiber marking lasers are available for integration into the machine to create
high-quality marks economically and reliably, even in low-volume productions.
The completely air-cooled laser sources are configurable and designed to be
almost maintenance-free. The M1000 also is supplied with integrated lighting, a
large window and an exhaust nozzle. It also can be equipped with a rotation axis.
FOBA / 49 38823 55 240 / fobalaser.com
 Mold Maintenance, Repair & Surface Treatment Pages 115 to 126

Laser Welding System Suited for Mold, Tool Makers

The HTS EVO mobile laser welding system from O.R. Laser was developed
specifically for mold, and tool and die makers, as well as mobile service pro-
viders. The system is equipped with Lilly software to enhance its automation
Polisher Accomodates Multiple Handpieces capabilities for use in aerospace, medical and production applications where
The Ultramax MF (multi-function) polisher from Gesswein Co. uses short stroke rotation axis and wire feeder accessories are used.
and fast reciprocation to polish slots, ribs and intricate details. Special control O.R. Laser / 847-593-5711 / or-laser.com
functions enable the user to polish right up to a wall or finish to an edge.
Offering the versatility of ultrasonic and mechanical polishing in one sys-
tem, the machine uses a high-efficiency microprocessor to deliver power to
ultrasonic, brushless DC and brush-type DC handpieces. The system includes Products Target
an H26 ultrasonic handpiece with 36 W of continuously variable power for Mold Cleaning,
precise reciprocating action, and it also can power any of the company’s Effciency
PowerHand rotary, reciprocating, side-to-side or belt sander handpieces. PCS Co. has added three prod-
The Ultramax MF can handle even tough metals such as tungsten carbide ucts to its mold efficiency and
and titanium. It can accommodate virtually all grades of finishing stones; sin- specialty cleaning line: Power
tered, resin and plated diamond tools; as well as ceramic stones, and metallic Clean, Mold Guard and Zap-Ox.
and nonmetallic lapping tools with diamond compounds. With an aggressive, chlori-
Gesswein & Co. / 203-366-5400 / gesswein.com nated cleaning agent that is
low-odor and residue-free,
Power Clean is formulated to
Mold/Die Tracking Software Adds Features effectively remove dirt and
MoldTrax 6 (MT6) software from ToolingDocs is designed specifically contaminates from the surfac-
for tracking the performance and maintenance of molds and dies. New es and pores of a mold. Its quick
features in the latest version include “Inventory Monitoring,” which evaporation capability enables
allows the user to quickly see how many parts are left in stock; a “Hot it to clean without wiping.
Runner Specs” tab in the TechTips section that gives users quicker Mold Guard rust preventa-
access to manifold maintenance and repair instructions, images tive goes on dry and stays dry, preventing corrosion to the mold. It features
and specifications of the system; a “Maintenance Alert” report that an adjustable-volume nozzle designed to provide spray control and reduce
enables the user to see the status of preventive maintenance (PM) on waste. The spray also is formulated to eliminate bleeding at startup and to
molds currently in production; a “Performance Dashboard” that shows provide high film strength.
the current ratio of scheduled to unscheduled mold stops, as well as Zap-Ox stain remover is formulated to remove rust, oxidation, buildup and
the number of molds currently in production and their PM status. weld discoloration, bringing metal back to its original state. It is safe to use on
ToolingDocs / 419-281-0790 / toolingdocs.com all metal surfaces and does not etch the surface, the company says.
PCS Co. / 800-521-0546 / pcs-company.com

moldmakingtechnology.com 125
Mold Maintenance, Repair & Surface Treatment
Being Data-
Driven Takes
More than Data
By Steve Johnson
To implement an accurate, efficient repair
and to optimize downtime hours, repair
technicians must have access to data to
quickly familiarize themselves with the
mechanical and performance characteris-
tics of every mold on which they work.
Repair technicians operate on and
maintain the heart of a plastics manu-
facturing company. They see, feel and decipher every type
of tooling fit (too loose, too tight or just right), track marks,
discoloration, wear and hob, looking for answers to immediate
and future issues. To do the job effectively, they need to know
not only about the smallest of details, such as minuscule toler-
ances and stack dimensions, but also the predominant, long-
term issues molds suffer as a result of design or build features
that cause problems during mold operation or maintenance
activities.
To make continuous improvements in a mold repair facility,
we must be able to measure specific metrics in order to set tar-
gets and goals for molds and personnel. The only substitute for
a data-driven approach to mold repair is money—lots of it.
In today’s economy, it is becoming more and more com-
monplace for the customer to ask such questions of their mold
vendors simply because they want to know exactly what is
going on with their half-million-dollar mold. So if you don’t
supply this data for your repair technicians, you might have to
for your customers.
Following are 10 questions that will demonstrate the cur-
rent level of data utilization that exists in your company that
is readily available for a repair technician, supervisor, manager
or engineer to use on a daily basis. If you cannot answer the
first three, you needn’t continue on, because the questions
continue to drill deeper into your mold-knowledge database.
Be aware that if it is necessary to dig through files of records
to manually count occurrences and gather data, then the infor-
mation in the system is not considered readily available.
Performance and maintenance data (broken down by chosen
timeframe):
1. What are your top 10 reasons for unscheduled mold stops?
(unscheduled downtime)
2. What are your top 10 part or product defects? (loss of pro-
duction/mold cavitation)
126 MoldMaking Technology July 2014
Pages 115 to 126
Photo courtesy of ToolingDocs.
Cosmetic Specialties International employees document critical mold data.
3. What are your top 10 mold frame issues? (issues with the
mold—not the part)
4. What are your top 10 molds with the highest maintenance
costs per hour? (tooling and labor used per hour or cycle of run
time)
5. What is your “on-time” PM percentage, based on your
own company/shop goals?
6. What are your top 10 worst-performing molds, based on
cavitation? (number of cavities blocked)
7. What are your top 10 worst-performing molds, based on
cycle time efficiency? (standard vs. actual)
8. What are your top 10 molds with the highest overall
defect counts?
9. What are your top 10 molds with the highest overall tool-
ing usage?
10. What are your top 10 molds with the highest overall
labor requirements?
Most shops, at a minimum, can quickly gather data con-
cerning money spent on tooling and labor. But this is only a
very small part of the picture. If you want your molds to run
reliably and produce the highest-quality parts with the least
possible amount of unscheduled downtime, you must take the
data that most shops typically collect and input it in a system
that will present it back to you in a format that will allow com-
plete utilization of it.
CONTRIBUTOR
Steve Johnson is operations manager for Tooling Docs.
FOR MORE INFORMATION:
ToolingDocs / 800-257-8369 / toolingdocs.com
COMBINED STRENGTH.
UNSURPASSED INNOVATION.
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Orlando, Florida / Orange County Convention Center

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REGISTRATION IS OPEN
MoldMaking Marketplace

American Composites Manufacturers Association (ACMA) 127 Methods Machine Tools, Inc 93
Bohler-Uddeholm 25 Micro 100 Tool Corporation 77
CGS North America Inc 11 Mitutoyo America Corporation 113
Cole Carbide Industries, Inc 81 Mold Base Industries, Inc 56
CUMSA USA LLC 58 Molding 2015 62
Dalton Electric Heating Co Inc 53 O R Lasertechnology Inc 119
Delcam North America 7 Omni Mold Sytems Inside Back Cover
DME Company 47 One Source 117
Doosan Infracore 91 PCS Company Insert, 45
Drill Masters-Eldorado Tool 75 PFA Inc 51
Edro Engineering 21 Poco Graphite Inc 107
Ellwood Specialty Steel 23 Practical Machinist 86
Haas Automation, Inc 89 Precision Ground Inc 57
Hasco America, Inc 49 Precision Laser Technology 128
Hurco Companies, Inc 1 Progressive Components Inside Front Cover, 128
IMTS 2014 39 Sandvik Coromant Back Cover
Incoe Corporation 33 Scientific Cutting Tools 73
Ingersoll Cutting Tools 69 Single Source Technologies 99
INglass SPA 37 Sumitomo Electric Carbide Inc 71
Iscar Metals, Inc 65 Techspex, Inc 40
LaserStar Technologies Corporation 121 Tool Alliance 83
Mason Dixon Design 128 TRAM 59
MC Machinery Systems, Inc 103 WALTER USA, Inc 67

MoldMaking Marketplace

Mason Dixon Design LLC.

Experienced Injection Mold Design

email: mason_dixon_design@yahoo.com
www.mason-dixon-design.com
777.759.0391

work in progress
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Join an engineering or sales team as we continue to grow,
setting new standards and supporting our customers.
To discuss, contact Glenn Starkey at gs@procomps.com.

To advertise in the Marketplace section of MoldMaking Technology

contact Chris Brock at (440) 639-2311 or cbrock@gardnerweb.com. Linkedin.com/in/gLennstarkeypcic | pcic-group.com

128 MoldMaking Technology July 2014

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Sandvik Coromant : Booth W-1500, IMTS 2014

www.sandvik.coromant.com/imts